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Swelling in battery cells, often caused by natural aging, SEI (Solid Electrolyte Interphase) growth and the decomposition of the electrolyte, has long been a challenge in ensuring mechanical integrity and long-term reliability. hofer powertrain’s solution combines real-time swelling force measurement with internal resistance tracking, giving engineers a direct correlation between mechanical expansion and electrochemical performance.

Within hofer powertrain’s battery development centre, cells are tested using a combination of high-resolution displacement sensors, force measurement sensors, and multi-channel battery testers. Test routines are conducted under precisely controlled thermal conditions, ranging from -40°C to +180°C , replicating real-world stress scenarios and enabling early identification of failure modes and associated performance loses of the cell.

hofer powertrain has established itself as a trusted partner for OEMs developing the most innovative battery testing methodologies worldwide. This advanced testing infrastructure is already in use for leading OEMs and Tier1 suppliers in Germany and now in the UK and supports both conventional lithium-ion and next-generation solid-state cell formats. By integrating swelling data into the validation process, hofer powertrain enables design teams to make informed decisions earlier, optimise module architecture, and reduce engineering effort in later stages.