Translating Test Results Into Design

When it comes to designing containers for specialized applications, especially for transporting sensitive equipment like helicopter blades or hazardous materials like lithium-ion batteries, testing plays a crucial role. It’s not just about determining if a design meets current needs; testing often uncovers hidden weaknesses and opportunities for improvement. The insights gained from testing can influence everything from material choices to structural reinforcements, ensuring that containers are both safe and future-proof.

How Testing Translates Into Design Improvements

During the testing process, engineers may discover that a container isn’t suitable for its intended application. Sometimes, a test is conducted more rigorously than necessary, revealing weaknesses that might not have been anticipated. For example, a container might be ideal for a customer’s current battery size but fail when tested for a larger, heavier battery. This signals the need for a design upgrade. This may include adding pressure-release channels, reinforcing the structure, integrating features that prevent gas buildup, or introducing other features that solve the uncovered challenge.

Drop testing is another critical evaluation method. A client might plan for a container to hold an 800-pound battery today but anticipate needing it for a 2,000-pound battery in the future. By testing beyond the expected weight limits, engineers can determine whether the design is robust enough or needs enhancements such as additional stiffeners or reinforced corners. These insights allow for proactive modifications, ensuring the container will meet both current and future demands.

Impact on Manufacturing Processes

Test results don’t just influence design, they can also affect the entire manufacturing workflow. For instance, if a drop test reveals that a container needs additional shock absorption to protect a sensitive piece of equipment, the production process must adapt. This might involve sourcing new components, adjusting the assembly sequence, or even modifying supplier relationships to ensure the necessary parts are developed to the new required specifications and arrive on time.

A recent project, for example, required specialized padding to cushion the impact during transportation. Since this component wasn’t originally part of the company’s standard manufacturing process, adjustments had to be made to integrate it seamlessly into production. The ability to pivot and refine processes based on test results is essential to delivering safe and effective solutions on schedule.

Navigating Regulations for Lithium-Ion Batteries

For lithium-ion battery containers, regulatory compliance is a major consideration. Different standards apply depending on where the battery will be used and which governing body oversees its certification. Some of the key regulatory bodies include:

• • Department of Transportation (DOT) 
• • Underwriters Laboratories (UL) 
• • Consumer Product Safety Commission (CPSC)
• • United Nations (UN)
• • International Maritime Organization (IMO)
• • European Union (EU)

For example, a battery pack used in a residential solar installation may have different safety requirements compared to one used in an industrial warehouse. Before companies can bring their products to market, they must ensure compliance with the relevant standards.

One major advantage of internal testing is the ability to refine designs before submitting them to certified test labs. Instead of testing an entire battery pack at once, engineers can analyze individual cells first, determining their volatility and adjusting the design as needed. Testing can then scale up to modules and full battery packs, ensuring a smoother path to certification.

Failure Analysis: Turning Setbacks Into Solutions

When a container or battery pack fails a test, the response can make all the difference. Unlike some labs that simply report a failure and return the equipment, a hands-on approach involves conducting a detailed “autopsy” of the failure. By opening the product, examining the components, and identifying the root cause, engineers can recommend targeted improvements.

The time required to resolve a failure depends on two main factors:

1. How well the client follows improvement recommendations – Implementing suggested changes can significantly speed up the redesign and retesting process.
2. Material availability – Prototyping often relies on specialized materials from various sources, such as 3D printing facilities or custom battery cell manufacturers. Lead times for these materials can impact how quickly a design iteration is ready for retesting.

Leveraging Industry Data for Smarter Designs

One of the most valuable aspects of continuous testing is the accumulation of shared industry knowledge. Many testing facilities participate in “round-robin testing” through UN subcommittees, where multiple labs globally conduct identical tests and share results. This collaborative data helps establish best practices and provides valuable benchmarks for new designs.

For instance, if a team has seen a particular container design fail repeatedly under similar conditions, they can advise against using it for certain applications. Conversely, they may identify when a client’s design is unnecessarily overbuilt, saving them time and money by recommending a simpler, yet equally effective solution.

Final Thoughts

Testing is far more than a pass/fail evaluation; it’s a crucial part of the design and manufacturing process that ensures safety, efficiency, and long-term reliability. By using test results to refine designs, adjust manufacturing workflows, and navigate regulatory requirements, companies can create more robust and future-proof container solutions. With a wealth of industry data and hands-on failure analysis, continuous testing not only prevents costly mistakes but also drives innovation and improvement at every stage.