--- title: Why DOT/UN 38.3 is Required for Lithium Batteries description: Learn why DOT/UN 38.3 testing is required for lithium batteries, the eight required tests, shipping limits, and impacts on cost and timelines. image: https://blog.epectec.com/hubfs/blog/lithium-battery-shipping-requirements.jpg --- [![Epec Engineered Technologies](https://www.epectec.com/images/logo.png "Epec Engineered Technologies")](https://www.epectec.com/) [![Epec Engineered Technologies](https://www.epectec.com/images/logo.png "Epec Engineered Technologies")](https://www.epectec.com/) - [Articles](https://www.epectec.com/articles/) - [Blog](https://blog.epectec.com/) - [Webinars](https://www.epectec.com/webinar/) - [Videos](https://www.epectec.com/videos/) - [Case Studies](https://www.epectec.com/case-studies/) - [News & Events](https://www.epectec.com/news/) - [Customer Portal](https://system.netsuite.com/c.406760/site/NSlogin.html) - [About](https://www.epectec.com/about/overview/) - Back - [Company Overview](https://www.epectec.com/about/overview/) - [Our History](https://www.epectec.com/about/our-history/) - [Culture](https://www.epectec.com/about/culture/) - [Industries Served](https://www.epectec.com/about/industry/) - [Acquisitions](https://www.epectec.com/about/acquisitions.html) - [Operations](https://www.epectec.com/operations/) - Back - [Operational Excellence](https://www.epectec.com/operations/) - [Quality Philosophy](https://www.epectec.com/operations/quality-philosophy.html) - [Quality Assurance Process](https://www.epectec.com/operations/quality-assurance-process.html) - [Global Operations](https://www.epectec.com/operations/global-operations.html) - [Logistics & Supply Chain](https://www.epectec.com/operations/logistics-and-supply-chain.html) - [Inventory Stocking](https://www.epectec.com/operations/inventory-stocking.html) - [Approvals](https://www.epectec.com/operations/approvals.html) - [ITAR Registered](https://www.epectec.com/operations/itar-registered.html) - [Engineering](https://www.epectec.com/engineering/overview/) - Back - [Engineering Overview](https://www.epectec.com/engineering/overview/) - [Engineering Support](https://www.epectec.com/engineering/support/) - [Design Services](https://www.epectec.com/engineering/design-services/) - [EpecDFx™](https://www.epectec.com/engineering/epecdfx/) - [Free DFM File Check](https://www.epectec.com/engineering/free-dfm.html) - [PCB Impedance Calculator](https://www.epectec.com/engineering/impedance-calculator.html) - [Products](https://www.epectec.com/products/) - Back - [Overview](https://www.epectec.com/products/) - [Battery Packs](https://www.epectec.com/batteries/) - [Flex & Rigid-Flex PCBS](https://www.epectec.com/flex/) - [Cable Assemblies](https://www.epectec.com/cable-assemblies/) - [Printed Circuit Boards](https://www.epectec.com/pcb/) - [CNC Machining](https://www.epectec.com/cnc-machining/) - [User Interfaces](https://www.epectec.com/user-interfaces/) - [Flexible Heaters](https://www.epectec.com/flexible-heaters/) - [EC Fans & Motors](https://www.epectec.com/fans-motors/) [Battery Packs![Custom Battery Packs](https://www.epectec.com/images/new-nav/flyout-battery-packs.png "Batteries and Custom Battery Packs")](https://www.epectec.com/batteries/) --- [CNC Machining![CNC Machining](https://www.epectec.com/images/new-nav/flyout-cnc-machining.png "CNC Machining")](https://www.epectec.com/cnc-machining/) [Flex & Rigid-Flex PCBs![Flex and Rigid-Flex Circuits](https://www.epectec.com/images/new-nav/flyout-flex-and-rigid-flex.png "Flex and Rigid-Flex Circuits")](https://www.epectec.com/flex/) --- [User Interfaces![User Interfaces](https://www.epectec.com/images/new-nav/flyout-user-interfaces2.png "User Interfaces Product Solutions")](https://www.epectec.com/user-interfaces/) [Cable Assemblies![Cable Assemblies](https://www.epectec.com/images/new-nav/flyout-cable-assemblies.png "Cable Assemblies")](https://www.epectec.com/cable-assemblies/) --- [Flexible Heaters![Flexible Heaters](https://www.epectec.com/images/new-nav/flyout-flexible-heaters.png "Flexible Heaters")](https://www.epectec.com/flexible-heaters/) [Printed Circuit Boards![Printed Circuit Boards](https://www.epectec.com/images/new-nav/flyout-printed-circuit-boards2.png "Printed Circuit Boards")](https://www.epectec.com/pcb/) --- [EC Fans & Motors![EC Fans and Motors](https://www.epectec.com/images/new-nav/flyout-fans-and-motors.png "EC Fans and Motors")](https://www.epectec.com/fans-motors/) - [Design Guides](https://www.epectec.com/guides/) - [Design Guides](https://www.epectec.com/guides/) - Back - Resources - Back - [Articles](https://www.epectec.com/articles/) - [Blog](https://blog.epectec.com/) - [Webinars](https://www.epectec.com/webinar/) - [Videos](https://www.epectec.com/videos/) - [Case Studies](https://www.epectec.com/case-studies/) - [News & Events](https://www.epectec.com/news/) - [Customer Portal](https://system.netsuite.com/c.406760/site/NSlogin.html) - [Contact Us](https://www.epectec.com/contact/) - Back - [Contact Information](https://www.epectec.com/contact/) - [Our Sales Team](https://www.epectec.com/contact/our-sales-team.html) - [Office Locations](https://www.epectec.com/contact/office-locations.html) - [Career Opportunities](https://www.epectec.com/contact/career-opportunities.html) - [InstantPCB*Quote*™](https://www.epectec.com/instantpcbquote/) - Back - [Overview](https://www.epectec.com/instantpcbquote/) - [Login](https://secure.epecpcb.com/epec/) - [Register](https://secure.epecpcb.com/epec/index2.jsp) [![](https://www.epectec.com/images/InstantPCBQuote-logo.png)](https://www.epectec.com/instantpcbquote/) [Login](https://secure.epecpcb.com/epec/) [Register](https://secure.epecpcb.com/epec/index2.jsp) Register to Quote and Order Your PCBs Fast, Easy & Online, 24/7 - [Home](https://www.epectec.com/) - [Blog](https://blog.epectec.com/) - Why DOT/UN 38.3 is Required for Lithium Batteries Share This Page: [LinkedIn](https://blog.epectec.com/#linkedin) [X](https://blog.epectec.com/#x) [Facebook](https://blog.epectec.com/#facebook) [Email](https://blog.epectec.com/#email) # Why DOT/UN 38.3 is Required for Lithium Batteries [![Anton Beck](https://blog.epectec.com/hubfs/Blog-Authors/anton-beck.jpg "Anton Beck")](https://blog.epectec.com/author/anton-beck) Written by [Anton Beck](https://blog.epectec.com/author/anton-beck) Posted on June 8, 2021 at 9:33 AM ![Anton Beck](https://blog.epectec.com/hubfs/Blog-Authors/anton-beck.jpg "Anton Beck") - [Tweet](https://twitter.com/share) [Lithium batteries](https://www.epectec.com/batteries/lithium-battery-technologies.html) are widely used in products that require high energy density, lightweight construction, and compact form factors. Applications such as cell phones, tablets, laptops, and other [portable electronic systems](https://www.epectec.com/batteries/custom-battery-packs-for-portable-electronic-devices.html) rely on lithium-based chemistries because they can deliver significant power in relatively small packages. While these performance advantages have accelerated their adoption, lithium batteries also require additional safety controls and transportation testing that are not required for many other battery technologies. Before lithium and lithium-ion batteries can be transported through the supply chain, they must meet specific testing requirements designed to verify that they can withstand [transportation conditions](https://blog.epectec.com/guide-to-shipping-lithium-batteries) without creating hazards to people, property, or equipment. [![Free Download: Choosing the Proper Lithium Battery for Your Product](https://no-cache.hubspot.com/cta/default/707152/1c15f534-a7c9-483c-9e91-e90f1f996120.png)](https://cta-redirect.hubspot.com/cta/redirect/707152/1c15f534-a7c9-483c-9e91-e90f1f996120)![Lithium battery shipping requirements](https://blog.epectec.com/hs-fs/hubfs/blog/lithium-battery-shipping-requirements.jpg?width=800&name=lithium-battery-shipping-requirements.jpg) *Example of lithium batteries that require DOT/UN 38.3.* ## Why Lithium Batteries Require Specialized Testing Lithium batteries contain lithium within their chemistry, which contributes to their [high energy density](https://www.epectec.com/batteries/cell-comparison.html) and low discharge rate. These characteristics make them attractive for a wide range of electronic products where maximizing energy storage while minimizing size and weight is important. The challenge is that lithium chemistry is highly reactive. If battery temperatures increase too rapidly during charging or operation, thermal runaway can occur. Under these conditions, batteries may vent hot gases, generate excessive internal pressure, or experience other hazardous failures. As lithium battery technology evolved, manufacturers transitioned toward lithium-ion chemistries that offered lower energy density than lithium metal batteries while still providing approximately twice the energy density of [nickel-based batteries](https://www.epectec.com/batteries/nickel-battery-technologies.html) and four times that of lead-acid batteries. Lithium-ion technology also maintained a low self-discharge rate and eliminated the need for prolonged battery priming. Because of the risks associated with lithium-based chemistries, battery packs incorporate safety controls designed to monitor battery operation and help prevent dangerous conditions from developing. ## The Role of Battery Management Systems Lithium battery packs require a [battery management system](https://www.epectec.com/batteries/battery-management-systems.html) (BMS) as part of their overall safety architecture. A BMS incorporates electronic protection circuitry and other safety mechanisms that monitor battery conditions during charging and discharging. These systems are designed to detect operating conditions that may exceed safe limits and initiate protective responses when necessary. **Depending on the event being detected, protective functions may:** - Control or interrupt current flow. - Respond to excessive temperatures. - Help manage elevated cell pressures. - Prevent over-discharge conditions. - Protect cell voltage from dropping below the recommended 2.5V per cell threshold. Battery management and protection systems are important because lithium batteries are classified as hazardous materials under transportation regulations. Testing therefore evaluates both battery design and the effectiveness of associated protection systems. ## Why DOT/UN 38.3 Testing Is Required Lithium batteries are classified as United Nations Class 9 Dangerous Goods. Because of this classification, manufacturers must demonstrate that battery designs can safely withstand conditions encountered during transportation. DOT/UN 38.3 testing was established to evaluate lithium battery safety during shipment. The standard is referenced in both the United Nations Manual of Tests and Criteria and United States Department of Transportation regulations. Because lithium batteries are routinely shipped across international borders, the requirements have been adopted internationally and apply regardless of whether batteries are transported by air, rail, roadway, or sea. **The purpose of testing is to identify potential hazards such as:** - Venting - Leakage - Flames - Other dangerous failures that may occur during transportation. ## When DOT/UN 38.3 Applies DOT/UN 38.3 testing requirements apply throughout the battery supply chain. **Testing applies when batteries are transported:** - From suppliers to manufacturers - From manufacturers to retailers - From retailers to distributors - During product returns The requirements apply whether batteries are shipped independently or installed within a product. They also apply to batteries that have already been used in the field and are being shipped outside their original packaging. ## The Eight Required DOT/UN 38.3 Tests DOT/UN 38.3 consists of eight tests that evaluate both mechanical and electrical performance under transportation-related conditions. ### T1 – Altitude Simulation This low-pressure test simulates transportation conditions equivalent to an aircraft's unpressurized cargo area at an altitude of 15,000 meters. ### T2 – Thermal Test The thermal test evaluates battery performance under repeated temperature extremes. Batteries are stored for 6 hours at temperatures ranging from -40°C to 70°C across multiple cycles. ### T3 – Vibration Test This test simulates the vibration conditions that batteries may encounter during transportation. ### T4 – Shock Test The shock test evaluates the battery's ability to withstand transportation-related shock events. ### T5 – External Short Circuit Test This test simulates a short circuit occurring at the battery or cell's external terminals. ### T6 – Impact Test The impact test simulates physical impact to the battery. For cylindrical cells measuring less than 30 mm, the test is performed directly on the cell case. ### T7 – Overcharge Test The overcharge test evaluates how rechargeable or secondary batteries respond to overcharge conditions. ### T8 – Forced Discharge Test The forced discharge test evaluates battery behavior under forced discharge conditions. ## Which Batteries Receive Which Tests? Not every test applies to every battery type. - **T1 through T6** are performed on primary and secondary batteries. - **T7** is performed only on secondary and rechargeable batteries. - **T8** is performed on primary and secondary batteries. Testing is typically conducted by accredited organizations and laboratories capable of performing DOT/UN 38.3 evaluations and issuing certifications. Organizations can become ISO17025 accredited to help ensure their testing processes comply with national and international standards. In certain situations, certification testing must be repeated, including circumstances where battery or product designs are modified before final shipment. ## Lithium Battery Test Summary Requirements Additional United Nations requirement that became effective in January 2022. Under the UN Manual of Tests and Criteria, Part III, Subsection 38.3, Paragraph 38.3.5, manufacturers and distributors are required to make lithium battery test summaries available. These summaries may be provided through a manufacturer's website, a distributor's website, or as part of a product information sheet. ## Shipping Quantity Restrictions DOT/UN 38.3 transportation requirements also establish limits on the quantity of lithium batteries that can be shipped on aircraft. For lithium metal batteries, restrictions are based on lithium content. For lithium-ion batteries, restrictions are based on watt-hour ratings. The following limits for the net quantity of batteries that are not combined within the same package. ### Lithium Metal Cell Batteries - **Less than 0.3 g lithium content** - No quantity limitation per package. - **More than 0.3 g but less than 1 g lithium content** - Maximum of 8 cells per package. - **More than 0.3 g but less than 2 g lithium content** - Maximum of 2 batteries per package. ### Lithium-Ion Cells and Batteries - **Less than 2.7 Wh** - No quantity limitation per package. - **More than 2.7 Wh but less than 20 Wh** - Maximum of 8 cells per package. - **More than 2.7 Wh but less than 100 Wh** - Maximum of 2 batteries per package. ## How UN 38.3 Affects Custom Battery Pack Development Compliance testing should be included in the early planning stages of a custom battery pack program. Certification testing typically requires approximately 16 battery packs for evaluation. Testing may take 4 to 6 weeks to complete and can cost approximately $5,000 to $7,000. These requirements can affect development budgets, project schedules, and product launch timelines. Understanding testing requirements early in the development cycle helps organizations account for certification activities before final production and shipment. ## Summary Lithium batteries and lithium-ion batteries go through extensive testing to ensure that they are safe to use for the specified product and application. Due to testing requirements, a certain number of packs (16) will typically need to be sent off for testing. The testing can take up to 4-6 weeks and create an estimated cost of about $5,000-$7,000. Customers need to take these factors into consideration when [developing a custom battery pack](https://www.epectec.com/batteries/development-stages.html), including development costs and timetable expectations for their product's time to market. --- ## Key Takeaways - **Safety concerns drive regulation:** Lithium and lithium-ion batteries pose risks such as thermal runaway, venting, or even explosion, making standardized safety testing essential. - **DOT/UN 38.3 testing is mandatory:** All lithium-based batteries must pass a series of 8 mechanical and electrical tests (altitude, thermal, vibration, shock, short circuit, impact, overcharge, forced discharge) before being transported. - **Certification ensures global compliance:** Because lithium batteries are classified as UN Class 9 Dangerous Goods, UN 38.3 is recognized internationally, covering shipment by air, sea, rail, and road. - **Shipping limits apply:** Packaging rules restrict how many cells or batteries can be shipped together based on lithium content or watt-hour ratings, reducing transport risks. - **Testing impacts cost and timeline:** Certification typically requires 16 sample packs, 4–6 weeks of testing, and costs around $5,000–$7,000, which must be factored into custom battery development planning. - [Tweet](https://twitter.com/share) Topics: [Battery Packs](https://blog.epectec.com/topic/battery-packs) --- [Next](https://blog.epectec.com/common-pcb-quality-issues-and-what-to-inspect-for) | [All posts](https://blog.epectec.com/all) | [Previous](https://blog.epectec.com/circuit-board-material-tolerances-that-affect-manufacturing) [![New Call-to-action](https://no-cache.hubspot.com/cta/default/707152/1b6bce74-ccab-4ed3-be09-66f7bd27ec08.png)](https://cta-redirect.hubspot.com/cta/redirect/707152/1b6bce74-ccab-4ed3-be09-66f7bd27ec08) ## Leave a Comment --- ## Related Posts --- ### Recent Posts --- ### Posts by Topic - [Printed Circuit Boards (161)](https://blog.epectec.com/topic/printed-circuit-boards) - [Product Design (138)](https://blog.epectec.com/topic/product-design) - [Battery Packs (121)](https://blog.epectec.com/topic/battery-packs) - [Cable Assemblies (102)](https://blog.epectec.com/topic/cable-assemblies) - [Flex & Rigid-Flex PCB's (95)](https://blog.epectec.com/topic/flex-rigid-flex-pcbs) - [Electronics Industry (61)](https://blog.epectec.com/topic/electronics-industry) - [User Interfaces (55)](https://blog.epectec.com/topic/user-interfaces) - [Quality Solutions (33)](https://blog.epectec.com/topic/quality-solutions) - [Flexible Heaters (30)](https://blog.epectec.com/topic/flexible-heaters) - [Events, Training, and Support (9)](https://blog.epectec.com/topic/events-training-and-support) - [RF Products (7)](https://blog.epectec.com/topic/rf-products) - [CNC Machining (3)](https://blog.epectec.com/topic/cnc-machining) - [Fans & Motors (1)](https://blog.epectec.com/topic/fans-motors) See All --- --- ### Need Help with A Project? [![Request Design Support](https://blog.epectec.com/hs-fs/hubfs/blog/design-support-ad.jpg?width=350&name=design-support-ad.jpg)](https://info.epectec.com/request-design-support) Our team of engineers are here to help you with all your product needs. [Request Design Support](https://cta-redirect.hubspot.com/cta/redirect/707152/0d3cd574-22cb-48a2-867e-1a7ffba28403) Manufacturing That Eliminates Risk & Improves Reliability [sales@epectec.com](mailto:sales@epectec.com?subject=Website%20Information%20Request) [(888) 995-5171](tel:888-995-5171) ##### Support & Contact Our knowledgeable staff has many years of experience in the industry. We welcome the opportunity to put our skills to work for you! Please contact us with any questions or requests. - [176 Samuel Barnet Blvd, New Bedford, MA](https://maps.app.goo.gl/Q6JVMv3eQgw29fNY8) - [sales@epectec.com](mailto:sales@epectec.com?subject=Website%20Information%20Request) - [(888) 995-5171](tel:888-995-5171) --- ###### Certifications [![UL Certified Manufacturer](https://www.epectec.com/images/certified-ul.png "UL Certified Manufacturer")](http://www.ul.com/) [![ITAR Registered Manufacturer](https://www.epectec.com/images/certified-itar.png "ITAR Registered Manufacturer")](https://www.epectec.com/operations/itar-registered.html) [![RoHS Compliant Manufacturer](https://www.epectec.com/images/certified-rohs-compliant.png "RoHS Compliant Manufacturer")](https://www.epectec.com/pcb/rohs-compliant.html) [![ISO9001 Certified Manufacturer](https://www.epectec.com/images/certified-iso9001.png "ISO9001 Certified Manufacturer")](https://www.epectec.com/operations/approvals.html) [![ISO27001 Certified Manufacturer](https://www.epectec.com/images/certified-iso27001.png "ISO27001 Certified Manufacturer")](https://www.epectec.com/operations/approvals.html) --- - ##### About - [Company Overview](https://www.epectec.com/about/overview/) - [Our History](https://www.epectec.com/about/our-history/) - [Culture](https://www.epectec.com/about/culture/) - [Industries Served](https://www.epectec.com/about/industry/) - [Acquisitions](https://www.epectec.com/about/acquisitions.html) - ##### Operations - [Operational Excellence](https://www.epectec.com/operations/) - [Quality Philosophy](https://www.epectec.com/operations/quality-philosophy.html) - [Quality Assurance Process](https://www.epectec.com/operations/quality-assurance-process.html) - [Global Operations](https://www.epectec.com/operations/global-operations.html) - [Logistics & Supply Chain](https://www.epectec.com/operations/logistics-and-supply-chain.html) - [Inventory Stocking](https://www.epectec.com/operations/inventory-stocking.html) - [Approvals](https://www.epectec.com/operations/approvals.html) - [ITAR Registered](https://www.epectec.com/operations/itar-registered.html) - ##### Engineering - [Engineering Overview](https://www.epectec.com/engineering/overview/) - [Engineering Support](https://www.epectec.com/engineering/support/) - [Design Services](https://www.epectec.com/engineering/design-services/) - [EpecDFx™](https://www.epectec.com/engineering/epecdfx/) - [Free DFM File Check](https://www.epectec.com/engineering/free-dfm.html) - [PCB Impedance Calculator](https://www.epectec.com/engineering/impedance-calculator.html) - ##### Products - [Overview](https://www.epectec.com/products/) - [Battery Packs](https://www.epectec.com/batteries/) - [Flex & Rigid-Flex PCBS](https://www.epectec.com/flex/) - [Cable Assemblies](https://www.epectec.com/cable-assemblies/) - [Printed Circuit Boards](https://www.epectec.com/pcb/) - [CNC Machining](https://www.epectec.com/cnc-machining/) - [User Interfaces](https://www.epectec.com/user-interfaces/) - [Flexible Heaters](https://www.epectec.com/flexible-heaters/) - [EC Fans & Motors](https://www.epectec.com/fans-motors/) ##### Social Community Join our Social Community and keep in touch with all our latest technology investments, current news, upcoming events, and promotions. --- © 2026 Copyright Epec, LLC. All Rights Reserved. [Tariff Resources](https://www.epectec.com/tariff-resources/)|[Privacy Policy](https://www.epectec.com/privacy-policy/)|[Term & Conditions](https://www.epectec.com/terms/site.html)|[Sitemap](https://www.epectec.com/sitemap.html) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Anton Beck", "url" : "https://blog.epectec.com/author/anton-beck" }, "dateModified" : "2026-09-30T12:52:54.731Z", "datePublished" : "2021-06-08T13:33:00.000Z", "headline" : "Why DOT/UN 38.3 is Required for Lithium Batteries", "image" : [ "https://blog.epectec.com/hubfs/blog/lithium-battery-shipping-requirements.jpg" ], "mainEntityOfPage" : { "@id" : "https://blog.epectec.com/why-dot-un-38.3-is-required-for-lithium-batteries", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://blog.epectec.com/hubfs/image/logo.png" }, "name" : "Epec Engineered Technologies" } } ```