Experimental and Simulation-Based Mechanical Testing of Lithium-Ion Battery Form Factors at Cell and Pack Levels under Drop, Impact, and Vibration Loads

Abstract

The increasing adoption of Electric Vehicles (EVs) and portable energy systems has intensified the need to ensure the structural integrity and safety of lithium-ion batteries under various mechanical loading scenarios. This study presents a comprehensive experimental and simulation-based investigation of the mechanical response of different lithium-ion battery form factors at both the cell and pack levels, subjected to drop, impact, and vibration loads. The experimental analysis involved controlled drop and impact tests to replicate handling, transportation, and crash conditions, while vibration tests simulated real-world operational environments. Complementary Finite Element (FE) simulations were developed to replicate the physical tests, enabling detailed insight into stress distribution, deformation behavior, and potential failure zones within the battery structures. Multiple form factors, including cylindrical, prismatic, and pouch cells, were evaluated to examine their distinct structural responses and failure modes. Key mechanical parameters such as displacement, strain, stress distribution, and onset of structural damage were analyzed. The simulation models were validated against experimental results, demonstrating strong correlation and predictive accuracy. This integrated approach enables the identification of critical mechanical vulnerabilities and contributes to the development of more robust battery pack designs. The findings of this study offer valuable insights for improving battery safety standards, optimizing structural design, and supporting regulatory compliance in EV and energy storage applications. Additionally, the validated simulation framework provides a cost-effective tool for early-stage design evaluation, reducing the need for extensive physical prototyping.