Battery testing systems are at the heart of R&D in lithium‑ion, solid‑state, and next‑generation battery technologies. Tools like NEWARE battery cyclers are trusted worldwide for their precision, modularity, and real‑time data analysis. However, even experienced scientists and engineers sometimes fall into pitfalls that affect accuracy, efficiency, or long‑term equipment performance.

Whether you are setting up a battery research lab or scaling your testing capacity, these are the seven most common mistakes researchers make when selecting or using battery testing systems — and how to avoid them.

1. Choosing a system with no room to scale

One of the biggest mistakes is buying a testing system that only meets current needs. If your lab grows, or you want to test more cells simultaneously, you might end up stuck with a system that cannot be expanded. Many entry‑level systems do not support additional channels, auxiliary temperature sensors, or rack expansion.

This is especially common in early‑stage research groups or university labs that plan for one chemistry or format but later diversify.

How to avoid it: Choose a modular system from the start. NEWARE’s multi‑channel systems allow you to add more testers or integrate high‑precision channels later. Ask your supplier if the hardware and software support expansion without replacing the core platform.

2. Ignoring software compatibility and update cycles

Scientists often overlook the importance of software in battery testing. Without stable software, a high‑spec testing unit becomes a source of data headaches. Some users fail to update the BTS software regularly or ignore compatibility issues between the BTS client and BTSDA (data analysis software).

This can result in incomplete logs, failed uploads, or incompatible batch scripts.

How to avoid it: Always use the latest stable version of NEWARE software. Verify compatibility between operating systems and BTS versions. If you are scaling your team, ensure the system supports multi‑user environments and proper role permissions for data integrity.

3. Improper configuration of C‑rate and cut‑off conditions

Misunderstanding C‑rate parameters is a leading cause of inaccurate test results. Users often fail to properly set “C‑rate mode” in the software, or they confuse it with current in mA or A, which can lead to overcharging or undercharging.

Additionally, incorrect voltage cut‑offs or rest periods between steps can distort capacity readings or shorten cell lifespan.

How to avoid it: Understand the relationship between your cell’s capacity and the desired current. NEWARE allows you to choose C‑rate directly, so activate it in the script interface. Set voltage limits and temperature boundaries based on your specific chemistry. Test scripts thoroughly with dummy cells first.

4. Using the wrong clamps or poor connection methods

Electrical contact is one of the most underestimated factors in battery testing. Some researchers use generic clamps that do not fit their cell format properly, leading to unstable readings, contact resistance, or even damage to the cell terminals.

Poor connections also increase the risk of arcing or overheating during high‑current testing.

How to avoid it: Use clamps designed for your specific cell type — prismatic, pouch, cylindrical, or coin. NEWARE offers different fixtures for different formats. Ensure that contacts are clean and tightened correctly, without damaging the terminal area. Use spring‑loaded probes for sensitive formats like pouch cells.

5. Skipping safety protocols and auxiliary monitoring

Battery testing carries inherent risks. Failing to monitor temperature, voltage anomalies, or reverse polarity can lead to dangerous situations, especially during abuse testing or with unstable chemistries.

Many users do not activate software safety features or fail to integrate thermal probes, assuming that the system’s default settings are enough.

How to avoid it: Set upper and lower voltage and temperature limits in each test script. Use thermocouples and integrate them with the system to shut down tests automatically in case of overheating. NEWARE allows you to configure emergency shutdown logic in both hardware and software.

6. Not allowing cells to rest before initial testing

This is a classic rookie error. After assembly or welding, batteries need time to stabilize before they are cycled. Skipping this rest phase can cause inaccurate first‑cycle data, inconsistent behavior, and misinterpretation of cell performance.

For example, button cells often require three to six hours of rest after crimping before any electrochemical testing.

How to avoid it: Build a rest step into your script, especially for new or lab‑assembled cells. Monitor open‑circuit voltage during the rest phase to confirm stability before cycling. The time you invest in waiting will pay off in better accuracy and reproducibility.

7. Running tests with too few cells to draw conclusions

Many researchers run tests on one or two cells, then extrapolate performance claims — but cells vary, even within the same batch. A single test cannot reveal the full behavior profile of a cell chemistry or design.

This mistake leads to poor statistical validity and misleading conclusions.

How to avoid it: Test at least five to ten cells per condition for research‑grade results. Use the NEWARE software’s batch control and data export tools to analyze multiple channels simultaneously. Look at standard deviation, not just average performance.

✅ Summary Table

Battery testing is more than connecting a cell and pressing Start. It requires attention to software configuration, electrical contact, thermal management, and experimental design. Avoiding these seven mistakes will help you produce reliable, safe, and scalable results.

Whether you're optimizing lithium-ion cathodes or characterizing next-gen solid-state designs, investing time in setup and understanding your equipment will directly impact your research outcomes.

📚 References

NEWARE Technical Guide – BTS Software Configuration
https://www.neware.net/supports/bts-tutorial.html

NEWARE User Manual – Clamp Types and Cell Compatibility
https://www.newarelab.com/images/newaretester/Download/Neware-User-Manual-Neware-Battery-Testing-System.pdf

NEWARE Safety Integration Practices – Thermal Cutoffs and Reverse Polarity
https://www.neware.net/news/how-to-choose-the-right-battery-cycling-test-system/230/121.html

NEWARE Cycling Protocol Recommendations – C-rate and Script Modes
https://www.newarelab.com/support/neware-manual

BTSDA Data Analysis Manual – Channel Statistics and Batch Reports
https://www.neware.net/supports/btsda-tutorial.html

Complete Guide to Button Cell Testing – NEWARE Learning Center
https://www.neware.net/news/complete-guide-to-button-cell-battery-manufacturing-and-testing/230/119.html

Statistical Sampling Guidelines for Battery Testing – arXiv Preprint
https://arxiv.org/abs/2107.07881

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7 Common Mistakes Scientists Make When Selecting or Using NEWARE Battery Testing Systems