As a standardized testing method that simulates real-world transportation environments, the 1.2m Drop Test is a critical means of evaluating the safety and reliability of battery product packaging. It directly relates to the product’s transportation safety and compliance with regulations.

In global battery product trade, accidental drops during transportation are one of the primary causes of product damage. The 1.2m Drop Test simulates potential drops during handling and shipping, assessing the impact resistance and protective performance of battery products and their packaging. It has thus become an indispensable testing step to ensure battery transportation safety.

01. What Is the 1.2m Drop Test?

The 1.2m Drop Test is a standardized method for simulating potential drops in transportation environments. It is primarily used to evaluate the protective performance and structural integrity of battery product packaging. The test requires a fully packaged battery product to be freely dropped from a height of 1.2 meters onto a hard, flat horizontal surface. The goal is to verify whether the product and its packaging can withstand the impact of the drop without sustaining damage or creating safety hazards.

To comprehensively assess the packaging’s impact resistance in all directions, the test typically involves multiple drops in different orientations (e.g., corner, edge, face). This drop height is determined based on international standards, derived from statistics and research on drop heights that may be encountered during transportation.

02. Why Do Battery Products Require the 1.2m Drop Test?

Battery products undergo multiple handling, loading/unloading, and transportation stages during shipping, making accidental drops unavoidable. For dangerous goods like lithium-ion batteries, drops can cause casing damage, internal short circuits, or even fires and explosions—making the drop test crucial:

1. Safety Requirements: Evaluate the safety performance of battery products when subjected to drop impacts, preventing hazards such as battery leakage, short circuits, fires, or explosions caused by drops.
2. Quality Verification: Inspect the rationality of product structural design and material selection, ensuring the product can withstand general impacts during transportation.
3. Regulatory Compliance: Meet the requirements of international transportation safety regulations (e.g., UN38.3) and various product quality standards.
4. Liability Definition: Provide objective evidence of product safety performance, serving as a basis for liability division in the event of transportation accidents.

03. Which Battery Products Require the 1.2m Drop Test?

Under international transportation regulations and standards, the following types of battery products typically require the 1.2m Drop Test:

By Product Type

• Lithium-ion batteries and battery packs
• Lithium-metal batteries and battery packs
• Lead-acid batteries
• Other battery types (e.g., nickel-metal hydride batteries)

By Transportation Method

• Batteries shipped independently (e.g., UN3480, UN3090)
• Batteries packaged with equipment (e.g., UN3481, UN3091)
• Batteries installed in equipment

By Regulatory Requirement

• Lithium-ion battery products requiring UN38.3 certification
• Battery-containing products requiring air transport identification reports
• Battery-containing products requiring marine shipping identification reports

04. Specific Requirements and Process of the 1.2m Drop Test

Test Sample Preparation

• Sample Quantity: At least 3 fully packaged samples are usually required.
• Sample Status: Samples must represent the actual transportation state, including internal batteries, cushioning materials, and outer packaging.
• Preconditioning: Depending on standard requirements, temperature and humidity preconditioning may be necessary.

Test Height

• Base Height: 1.2 meters.
• Adjustments by Weight: Height may be reduced if the product exceeds a certain weight (per specific standard provisions).

Drop Sequence

Tests are typically conducted in the following order:

1. Corner Drops: One drop for each corner of the package base.
2. Edge Drops: One drop for each edge of the package base.
3. Face Drops: One drop for each face of the package.

Test Surface

A hard, flat, non-deformable horizontal surface—usually concrete or steel plate.

Pass Criteria

After the test, the product must meet the following requirements:

• No weight loss, leakage, rupture, explosion, or fire in the battery.
• No severe deformation or damage to the package.
• The tested battery must still meet other safety requirements (e.g., short circuit testing).

05. Test Equipment and Environmental Requirements

Test Equipment

• Drop Tester: Capable of precisely controlling drop height and orientation.
• Height Measurement Device: Ensures accurate drop height.
• Sample Fixing Device: Keeps the sample stable before dropping.

Environmental Conditions

• Temperature: 20 ± 5°C.
• Humidity: Relative humidity ≤ 90%.
• No Strong Airflow: The test environment must be free from strong air disturbances.

06. How to Prepare for the 1.2m Drop Test?

To ensure successful completion of the 1.2m Drop Test, battery manufacturers should complete the following preparation work:

Packaging Design Optimization

• Material Selection: Choose packaging materials with excellent impact resistance.
• Structural Design: Optimize packaging structure, adding cushioning and protective features.
• Internal Fixation: Ensure batteries do not move inside the package.

Product Design Considerations

• Structural Strength: Enhance the structural strength of the battery casing.
• Internal Protection: Add internal safeguards (e.g., anti-short circuit designs).
• Sensitive Component Protection: Provide additional protection for sensitive components.

Pre-Test Preparation

• Sample Preparation: Prepare test samples that meet requirements.
• Document Preparation: Gather product specifications, design documents, and other materials.
• Pre-Testing: Conduct internal pre-tests to identify and address issues promptly.

07. Common Causes of Test Failure and Improvement Measures

Common Failure Causes

1. Insufficient Packaging Material Strength: Unable to effectively absorb impact energy.
2. Unreasonable Internal Cushioning Design: Fails to provide effective protection.
3. Battery Structural Defects: Inadequate impact resistance of the battery itself.
4. Improper Fixation: Batteries move inside the package, causing secondary impacts.

Improvement Measures

1. Strengthen Packaging Materials: Use higher-strength packaging materials.
2. Optimize Cushioning Design: Increase the thickness or density of cushioning materials.
3. Improve Structural Design: Reinforce the battery casing and internal structure.
4. Enhance Fixation Methods: Ensure batteries are securely fixed inside the package.

08. How to Choose a Professional Testing Service Provider?

Selecting a professional and reliable testing service provider is critical to ensuring the accuracy and international recognition of test results. A high-quality service provider should meet the following criteria:

• Qualifications and Accreditations: Possess laboratory accreditations such as CNAS (China National Accreditation Service for Conformity Assessment) or CMA (China Inspection Body and Laboratory Mandatory Approval).
• Testing Experience: Have extensive experience in testing battery products.
• Advanced Equipment: Be equipped with advanced testing equipment and instruments.
• Global Recognition: Have test reports widely accepted internationally.
• Comprehensive Services: Offer one-stop services from testing to certification.
• Technical Support: Be able to provide professional advice on technical improvements.

Conclusion

The 1.2m Drop Test is a key method for evaluating the transportation safety of battery products. By simulating real drop scenarios in transportation, it verifies the protective performance of products and their packaging. As global requirements for battery transportation safety continue to tighten, the drop test has become a critical focus for battery enterprises.

For battery manufacturers and traders, fully recognizing the importance of the 1.2m Drop Test and conducting product design and test preparation in strict accordance with standards is the foundation for ensuring smooth access to international markets. Choosing a professional testing partner and planning test strategies in advance will provide reliable guarantees for the international transportation safety of products.