Why This Battery Testing Facility Changes Everything
Here's the challenge that's plagued the battery industry: AI-powered software can analyze used battery cells and predict their state of health, but how do you know those predictions are accurate? How do you verify that a battery diagnosed as suitable for second-life applications will actually perform as expected in a stationary storage system or an electric vehicle?
The answer is rigorous, real-world battery testing—and that's exactly what our new testing facility delivers.
Bridging the Gap Between Digital Analysis and Physical Reality
Our battery lab serves a critical purpose: comparing, training, and verifying AI-supported software analyses against laboratory values obtained from real-life simulation. This dual approach creates an unprecedented data foundation that makes our battery health assessments the most accurate in the industry.
Think of it this way: Our AI analyzes millions of data points from a battery's first life. Our battery testing facility then puts those same batteries through comprehensive charge and discharge cycles under controlled conditions. When the real-world results validate the AI predictions, everyone in the battery supply chain benefits from increased confidence and precision.
The Team Behind the Testing
Depending on workload, up to six software and battery specialists work in the Circunomics battery lab. This team combines expertise in:
- Battery chemistry and lithium-ion batteries behavior
- AI and machine learning algorithms
- Data analysis and interpretation
- Safety protocols and testing procedures
- Battery supply chain optimization
Their work ensures that every data point collected contributes meaningfully to our data foundation and ultimately to better decision-making across the entire battery ecosystem.
Advanced Testing Capabilities
Multi-Cell Testing Infrastructure Our facility can house and test various battery cells simultaneously. Each cell is securely shielded within the testing facility and subjected to customized stress tests based on specific requirements and programs.
Real-World Battery Usage Simulation We don't just measure static battery capacity—we simulate actual battery usage scenarios that batteries experience in the real world:
- Electric vehicles (EVs) scenarios: Rapid and slow successive charging cycles that mirror real driving patterns
- Variable charging conditions: Charging voltage up to 300 amps DC, replicating both standard and fast charging environments
- Multiple degradation states: Testing batteries at various stages of battery degradation to understand performance trajectories
- Extreme temperature testing: From -20°C to 60°C, ensuring batteries perform across all climate conditions
- Flexible testing durations: Short-term assessments (days), medium-term monitoring (weeks to months), or long-term studies (up to two years)
This comprehensive approach to charge and discharge testing provides data points that go far beyond simple battery capacity measurements.
State-of-the-Art Safety Infrastructure
Battery testing involves inherent risks, which is why our facility features multiple layers of protection:
- CO₂ extinguishing system for fire suppression
- Round-the-clock monitoring via data transfer and camera recordings
- Secure cell shielding to contain any potential incidents
- Reliable power infrastructure supporting continuous operations and parallel analyses
- Professional safety protocols managed by trained battery specialists
The Data Foundation That Powers Precision
Every test conducted in our battery lab contributes to a growing data foundation—a comprehensive database that makes our AI predictions increasingly accurate over time.
How the Verification Process Works
Step 1: First-Life Data Collection During a battery's initial life in an electric vehicle, energy storage system, or other application, we collect millions of data points about its performance, battery usage patterns, and degradation characteristics.
Step 2: AI-Powered Analysis Our AI-supported software analyzes these data points to determine the current state of health and predict how the used battery cells will perform in second-life applications before eventual recycling.
Step 3: Laboratory Verification In our testing facility, we subject the same batteries to real-life simulation, observing actual behavior through controlled charge and discharge cycles.
Step 4: Comparison and Training We compare software predictions with laboratory results, using any discrepancies to further train and refine our AI algorithms.
Step 5: Enhanced Predictions This continuous feedback loop enables us to offer simulations and projections for second-life battery usage with exceptional accuracy and reliability.
As Jan Born, Co-Founder and CTO of Circunomics explains: "Until now, we had our cells analyzed by an external service provider. We are now moving this task in-house, which increases our efficiency and speeds up our data comparison. This enables us to offer our simulations and projections for second-life use with more accuracy and reliability."
Second-Life Battery Applications: From Theory to Reality
One of the most valuable outputs from our battery testing is the ability to make precise recommendations about which batteries are best suited for specific second-life projects.
Why Second-Life Matters
Not every battery that reaches the end of its first life needs immediate recycling. Many used battery cells retain 70-80% of their original capacity—perfectly suitable for less demanding applications than powering electric vehicles.
Our battery lab enables us to:
- Identify optimal second-life candidates through comprehensive battery performance testing
- Match batteries to applications based on verified capacity, discharge cycle characteristics, and degradation patterns
- Predict lifespan in second-life scenarios with data-backed confidence
- Optimize battery supply chain efficiency by extending the life of a battery before recycling
Second-Life Applications We Test For
Stationary Energy Storage (BESS) Former EV batteries can provide years of reliable service in stationary storage systems for renewable energy, data centers, or grid stabilization. Our battery testing verifies which cells meet the performance requirements for these applications.
Lower-Intensity Vehicle Applications Batteries no longer suitable for passenger electric vehicles might excel in municipal service vehicles, golf carts, or material handling equipment. Our testing facility identifies these opportunities.
Backup Power Systems Critical infrastructure, telecommunications, and emergency systems can benefit from second-life batteries. Our battery health assessments ensure reliability in these crucial applications.
Join the Battery Testing Revolution
The Circunomics battery lab represents a new standard in battery lifecycle management—where AI-powered predictions meet rigorous real-world verification, where data points become actionable intelligence, and where the battery supply chain becomes more transparent, efficient, and sustainable.
Our testing facility in Roßdorf is more than a collection of equipment and safety systems. It's a data foundation for the circular economy. It's a verification engine for AI innovation. It's a bridge between a battery's first life and its second life. And it's a commitment to accuracy, sustainability, and continuous improvement.
