In today’s thriving new energy industry, lithium batteries, as key energy storage carriers, are widely used in various fields such as consumer electronics, electric vehicles, and energy storage stations. To ensure the safety of lithium battery transportation, the United Nations has established the UN38.3 certification, which will undergo significant changes in 2025.

In 2025, UN38.3 certification will be particularly crucial.

In 2025, global trade in lithium batteries will continue to grow rapidly, with an increasing number of lithium battery products circulating internationally. At the same time, international transportation safety standards are continuously being upgraded, and regulations for the transport of lithium batteries are becoming increasingly strict. The UN38.3 certification serves as an important guarantee for the safe transport of lithium batteries and has become a “passport” for entering international markets.

From a policy and regulatory perspective, the International Air Transport Association (IATA) Dangerous Goods Regulations (DGR) Edition 66 will officially take effect on January 1, 2025, marking the largest adjustment to lithium battery transport standards and UN38.3 testing requirements in nearly a decade. The International Maritime Organization (IMO) also plans to update the International Maritime Dangerous Goods Code in 2026, which is expected to adopt new provisions related to lithium battery transport that are closely linked to UN38.3 certification. This means that whether by air or sea, compliance with UN38.3 certification is essential for transporting lithium batteries legally.

What is UN38.3 certification ?

UN38.3 certification refers to Section 38.3 of the “United Nations Manual of Tests and Criteria” for the transport of dangerous goods established by the United Nations. It is a safety performance testing report for lithium batteries, conducting comprehensive safety tests on various types of lithium batteries according to domestic and international standards to ensure product quality and transportation safety. In simple terms, it is a rigorous inspection of the transportation safety of lithium batteries.

Only after passing a series of strict tests, including altitude simulation, high and low temperature cycling, vibration testing, impact testing, external short circuit at 55°C, collision testing, overcharging tests, and forced discharge tests can a lithium battery ensure its safety during transport and obtain UN38.3 certification. If the lithium battery is not installed with equipment and each package contains more than 24 battery cells or 12 batteries, it must also pass a free fall test from 1.2 meters.

What does UN38.3 certification cover ?

1. Various disposable batteries: excluding lithium-manganese dioxide cells. Although disposable cells have specific scenarios for use, they also need to meet UN38.3 certification standards during transportation.

2. Various types of lithium-ion secondary batteries: such as batteries for electric vehicles, electric road vehicles, power tools, and hybrid vehicles. These batteries are widely used in new energy vehicles and power tools, making transportation safety crucial.

3. Various mobile phone batteries: including lithium-ion batteries and lithium polymer batteries. Mobile phones are indispensable electronic products in people’s daily lives, and the transportation safety of their batteries directly relates to consumer safety.

4. Various small secondary batteries: such as those used in laptops, digital cameras, camcorders, cylindrical wireless communication devices, and portable DVD, CD, and MP3 players. These small batteries are commonly used in various portable electronic devices and must comply with UN38.3 certification requirements during transport.

What are the new changes in UN38.3 certification for 2025 ?

1. New regulations related to sodium-ion batteries: With the commercialization of sodium-ion battery technology, the new regulations for 2025 establish an independent transport code for them for the first time. Sodium-ion batteries transported separately must use UN 3551, while those transported with equipment will use UN 3552. Due to their organic electrolyte characteristics, three new packaging provisions (PI 976, PI 977, PI 978) require the use of anti-static materials to isolate electrodes and mandate labeling on outer packaging with “moisture-proof” and “crush-proof” indicators.

2. Upgraded state of charge (SOC) management: Before December 31, 2025, it is recommended that lithium-ion/metal batteries maintain a charge below 30%. Starting January 1, 2026, cells or batteries over 2.7 watt-hours (Wh) must comply with this standard mandatorily. This requirement drives continuous technological upgrades in battery management systems (BMS), and some companies have developed smart chips capable of remotely locking battery charge.

3. Stricter label and document management: The original “lithium battery label” has been uniformly renamed as “battery label,” and a newly added Class Nine hazardous material label must clearly indicate whether it is “lithium-ion” or “sodium-ion.” In terms of document management, the new regulations require transport documents to specify total watt-hour capacity of the batteries, percentage state of charge, and version number of test reports.

Detailed Explanation of the Eight Tests for UN38.3 Certification.

1. Altitude Simulation Test: Under conditions of pressure ≤ 11.6 kPa and temperature 20±5℃, maintain for over 6 hours to simulate the situation of lithium batteries in high-altitude low-pressure environments, requiring no leakage, venting, disintegration, rupture, combustion, or other incidents to occur.

2. Thermal Test: Conduct high and low-temperature shock tests at 72±2℃ and -40±2℃; store at extreme temperatures for ≥6h with a temperature transition time ≤30min; perform 10 shocks; store at room temperature (20±5℃) for 24h; total test duration must be at least one week. This primarily checks the performance and safety of lithium batteries under extreme temperature changes.

3. Vibration Test: Complete one cycle of logarithmic sweep sine vibration from 7Hz to 200Hz within 15 minutes and conduct three-dimensional direction vibrations a total of 12 times within three hours. Simulates the impact of vibrations on lithium batteries during transportation to ensure structural and performance stability.

4. Impact Test: Apply half-sine impacts of either 150g for 6ms or 50g for 11ms in each mounting direction three times each, totaling eighteen impacts overall. Simulates potential impact situations that lithium batteries may encounter to assess their safety under such conditions.

5. External Short Circuit Test: Short circuit under conditions of temperature at 55±2℃ and external resistance <0.1Ω until battery temperature returns to around ±55℃ after an hour is completed post-short circuiting period.. This tests the safety of lithium batteries under external short-circuit conditions to prevent overheating or fire hazards.

6. Drop Test: A weight of 9.1kg is dropped from a height of approximately ±61cm onto a battery placed on a round rod measuring Ø15mm while monitoring surface temperatures on the battery itself .Simulates scenarios where lithium batteries are subjected to collisions ensuring there are no safety issues following such events.

7. Overcharge Test : Overcharge the battery continuously for twenty-four hours using double maximum continuous charging current along with double maximum charging voltage .This assesses how safe Lithium Batteries remain when overcharged avoiding any dangers arising due excessive charge levels .

8. Forced Discharge Testing : Connects Battery in series with twelve-volt direct current power supply performing forced discharge utilizing maximum discharge currents checking both performance & Safety aspects associated therein during this process .

UN38.3 Certification Process and Precautions.

1. Choose a certification body: Preferably select organizations with dual qualifications from CNAS (China National Accreditation Service for Conformity Assessment) / ILAC (International Laboratory Accreditation Cooperation), such as SGS, TUV, etc. These organizations have higher authority and recognition, and their issued certification reports are more likely to be accepted in the international market. Avoid choosing unqualified or partially qualified institutions to prevent acceptance issues with the certification report, which could delay processes and increase costs.

2. Prepare certification materials: Prepare detailed specifications for the battery cells, including capacity, voltage, chemical system information; provide structural diagrams of the battery pack clearly indicating BMS locations; prepare packaging design drawings that comply with IATA PI965 standards. Ensure accuracy and completeness of materials to avoid delays in the certification process due to documentation issues.

3. Sample preparation and shipping: Prepare 12 battery cells (6 for testing + 6 backup), clearly marked with capacity and polarity (laser engraving is best); prepare 4 battery packs (2 for testing + 2 backup) at full charge state (SOC ≤30%, otherwise air transport will be rejected). When sending samples, pay attention to packaging safety to prevent damage during transportation. Additionally, each model of modular battery packs must be declared separately to avoid failures due to mixed models during certification.

4. Certification testing process: The certifying agency will conduct eight tests on samples according to UN38.3 standards. During testing, companies can communicate with the certifying agency to understand progress and potential issues that may arise. For common failure items such as external short circuit (35%), thermal shock (28%), overcharge (22%), companies can conduct pre-tests during new product development stages to identify problems early on and improve formal test pass rates.

5. Report issuance and follow-up: After passing tests, the certifying agency will issue a UN38.3 test report that must indicate “UN38.3 Rev.7 (2025 version)” along with laboratory qualification numbers (e.g., CNAS L12345). The new regulations in 2025 require reports to include QR codes that allow tracing back production batches and recycling channels when scanned. After obtaining the report, companies also need to apply for a “Goods Transport Condition Certificate” through agencies like DGM or Bureau Veritas as proof of collection by airlines while ensuring compliance in lithium battery packaging—each box should not exceed 10kg when transported separately—and labeled “Lithium Ion Battery,” passing a drop test from 1 meter; when transported with equipment, batteries should be secured against friction short circuits alongside devices while each box requires an accompanying transport declaration stating emergency handling measures.

How to plan in response to the new regulations of 2025 ?

1. Plan certification time in advance: Given the strict requirements and complex certification process of the 2025 regulations, plan for UN38.3 certification 3-6 months in advance.

2. Strengthen technological research and improvement: In response to requirements such as state of charge control and thermal runaway propagation testing in the new regulations, increase investment in research and development related to battery management systems (BMS) and battery materials and structures.

3. Establish a compliance management system: Build a comprehensive compliance management system for lithium battery transportation, ensuring that every link from raw material procurement, product design, production manufacturing to packaging transportation strictly adheres to UN38.3 certification requirements and new regulations. Conduct regular compliance training to enhance awareness of compliance and ensure consistent adherence to international standards in lithium battery transportation.

4. Pay attention to international standard dynamics: International transport standards and UN38.3 certification requirements may be continuously updated with technological advancements and safety needs. Closely monitor updates from international organizations such as the International Air Transport Association (IATA), International Maritime Organization (IMO), as well as regulatory agencies from various countries regarding the latest standards and regulatory developments, adjusting production and transportation strategies promptly to ensure ongoing compliance status.

In the current international environment, it is ideal for our batteries to have UN38.3 certification to avoid any issues during international transport. However, sometimes for various reasons, the batteries may not have UN38.3 certification; how should they be transported?

1. If there are only a few lithium battery samples without UN38.3 certification, how should they be transported ?

If there are just a few lithium battery samples, based on the current situation, they can be shipped via international express delivery. The requirement is that each individual lithium battery must not exceed 7KG and the total weight of all lithium batteries in one box must not exceed 10KG.

2. If it is a small batch of lithium batteries without UN38.3 certification, how should they be transported ?

For small batches of batteries, we can currently arrange air freight to the destination airport or consolidated sea freight to the destination port using general version UN38.3 as long as the recipient can clear customs and pick up the goods. We can also arrange DDP mode transportation (specific circumstances need to be verified according to the destination country).