UN 38.3 Battery Safety Tests

All lithium batteries for air transport must pass UN 38.3 testing. This ensures they're safe at altitude.

The 8 Required Tests:

1. Altitude Simulation (T.1)

   • 6 hours at 50,000 ft (15,200m) equivalent pressure
   • Tests if battery swells or leaks at low pressure

2. Thermal Test (T.2)

   • Cycle between +72°C and -40°C
   • 6 hours at each extreme, repeated 10 times
   • Tests thermal stress tolerance

3. Vibration (T.3)

   • Simulates transportation vibration
   • Tests structural integrity

4. Shock (T.4)

   • Impact testing
   • Simulates rough handling

5. External Short Circuit (T.5)

   • Terminals shorted at 55°C
   • Must not explode or catch fire

6. Impact/Crush (T.6)

   • Physical damage testing
   • Tests what happens when crushed

7. Overcharge (T.7)

   • Charged beyond normal capacity
   • Li-ion only (rechargeable)

8. Forced Discharge (T.8)

   • Discharged beyond normal limits
   • Tests reverse polarity protection

What This Means for OBC:

✅ Reputable brands (Apple, Samsung, Sony, DJI) = all certified ⚠️ Cheap knockoffs may NOT be UN 38.3 certified = dangerous!

IATA Recommendation: Buy batteries only from trusted sources. Many aircraft incidents involve:

• Counterfeit batteries
• Substandard manufacturing
• Non-certified products

Documentation:

• Major manufacturers provide UN 38.3 test summaries
• May be requested by airlines for large/unusual batteries
• OnFlyGo recommends keeping records for 100-160Wh batteries