ISO 17546:2024

Space systems - Lithium ion battery for space vehicles - Design and verification requirements

This document specifies design and minimum verification requirements for lithium-ion batteries from the perspectives of performance, safety and logistics. This document is applicable to battery assemblies for space vehicles and component cells of batteries, which are critical devices to be harmonized with standards and regulations for other industries. In addition, this document is applicable to component cells which are not designed for space vehicles but can be used in space.

Systèmes spatiaux — Batteries à ions lithium pour véhicules spatiaux — Exigences de vérification et de conception

General Information

• Status: Published
• Publication Date: 18-Feb-2024
• ICS: 49.140 - Space systems and operations
• Technical Committee: ISO/TC 20/SC 14 - Space systems and operations
• Drafting Committee: ISO/TC 20/SC 14 - Space systems and operations
• Current Stage: 9092 - International Standard to be revised
• Start Date: 24-Jul-2025
• Completion Date: 13-Dec-2025

Relations

• Revises: ISO 17546:2016 - Space systems - Lithium ion battery for space vehicles - Design and verification requirements
• Effective Date: 06-Jun-2022

Overview

ISO 17546:2024 - Space systems - Lithium ion battery for space vehicles - Design and verification requirements defines design and minimum verification requirements for lithium‑ion batteries used in space vehicles. The standard addresses battery assemblies and component cells (including commercial off‑the‑shelf (COTS) cells that may be repurposed for space). Its primary focus areas are performance, safety and logistics, and it aims to harmonize space battery requirements with applicable industry standards and regulations.

Keywords: ISO 17546, lithium ion battery for space vehicles, space battery standards, battery design verification, Li‑ion space battery safety

Key Topics

ISO 17546 covers technical topics and verification activities at both the cell and battery level, including:

• Cell performance tests: qualification, capacity measurement, C/n charge/discharge currents (C‑rate), cut‑off voltage, self‑discharge, impedance and internal resistance, energy and energy density, nameplate and nominal capacity/voltage.
• Safety tests: hazard identification, safety testing, protective devices, fault tolerance and hazard control measures.
• Environmental verification: thermal and thermal‑vacuum testing, mechanical environment testing, leakage/hermeticity, radiation testing and life‑cycle testing.
• Battery design controls: electrical, thermal and mechanical design, cell‑to‑cell balancing, cell matching criteria and contamination control.
• Verification and qualification: development testing, flight verification acceptance testing, qualification test levels/durations, test data trending and life‑estimation assurance.
• Logistics and traceability: manufacturing, storage, handling, transportation, lot integrity assessment and mission conformance tests for COTS cells.

Applications and Who Uses It

ISO 17546 is intended for organizations involved in the design, procurement, testing and certification of space vehicle batteries:

• Spacecraft manufacturers and system integrators
• Battery and cell designers for space applications
• Suppliers and OEMs offering space‑rated or re‑qualified COTS cells
• Test laboratories performing thermal‑vacuum, mechanical, radiation and life‑cycle tests
• Mission assurance, quality and safety engineers responsible for hazard controls and fault tolerance
• Regulatory bodies and procurement teams seeking standardized verification criteria

Using ISO 17546 helps ensure consistent performance, reliable safety mitigation and predictable logistics for lithium‑ion batteries in space missions, from launch through end‑of‑life.

Related standards and guidance

ISO 17546 is intended to be harmonized with other industry and regulatory documents covering batteries and space systems. Relevant program requirements and sector standards (spacecraft system standards, battery transport regulations and battery safety standards) should be consulted alongside ISO 17546 for complete compliance and mission conformance.

Standards Content (Sample)

International
Standard
ISO 17546
Second edition
Space systems — Lithium ion
2024-02
battery for space vehicles — Design
and verification requirements
Systèmes spatiaux — Batteries à ions lithium pour véhicules
spatiaux — Exigences de vérification et de conception
Reference number
© ISO 2024
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ISO copyright office
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Published in Switzerland
ii
Contents Page
Foreword .vi
Introduction .vii
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Symbols and abbreviated terms. 6
5 Cell . 6
5.1 Performance .6
5.1.1 General .6
5.1.2 Test requirements .7
[4]
5.1.3 Test data trending .7
5.1.4 Cell qualification test .8
5.1.5 Leakage (hermetic) test .8
5.1.6 Safety tests .8
[5]
5.1.7 Thermal/thermal vacuum test .8
5.1.8 Mechanical environmental test.8
5.1.9 Radiation test .9
5.1.10 Life cycle test .9
5.1.11 Models for analysis .10
5.2 Safety.10
5.2.1 General .10
5.2.2 Hazard description .10
5.2.3 Protective devices as a hazard control .10
5.2.4 Safety testing .11
5.2.5 Important test considerations . 12
5.2.6 Optional test . 13
5.3 Logistics . . 13
5.3.1 General . 13
5.3.2 Cell manufacturing, storage and testing .14
5.3.3 Safety measure for handling .14
5.3.4 Cell transportation . 15
5.4 COTS cells for space use . 15
5.4.1 General . 15
5.4.2 Safety requirements . 15
5.4.3 Lot integrity assessment . 15
5.4.4 Mission conformance test . 15
5.4.5 Charge and discharge test . 15
5.4.6 Thermal vacuum test .16
5.4.7 Mechanical environment test .16
5.4.8 Cycle life test .16
5.4.9 Storage life test .16
6 Battery . 16
6.1 Performance .16
6.1.1 General .16
[4][5][6]
6.1.2 C/n charge or discharge current (c-rate) .16
6.1.3 Cut-off voltage .16
6.1.4 Cycle .17
[4][5][6][13]
6.1.5 Depth of discharge (DOD) .17
6.1.6 End of charge voltage .17
6.1.7 Energy .17
6.1.8 Energy density .17
[4][5]
6.1.9 Energy reserve .18
[9][13]
6.1.10 Fully charged .18

iii
6.1.11 Nameplate capacity .18
6.1.12 Nominal capacity .18
[5][12]
6.1.13 Nameplate energy .18
[9]
6.1.14 Nominal voltage .18
6.1.15 State of charge .18
6.1.16 Standard method for capacity measurement .19
6.1.17 Battery internal resistance (ohmic) .19
6.1.18 Battery impedance .19
6.1.19 Life test demonstration .19
6.1.20 For GEO simulated. 20
6.1.21 For LEO simulated . 20
6.1.22 For launch vehicle: simulate ground storage and usage at launch phase . 20
[5][11]
6.1.23 Battery general requirements . 20
6.1.24 Electrical design .21
6.1.25 Thermal design .21
6.1.26 Mechanical design .21
6.1.27 Cell-to-cell balancing mechanisms . .21
6.1.28 Marking . . .21
6.1.29 Cell matching .21
6.1.30 Polarization testing (optional) .21
6.1.31 Self-discharge rate test . 22
6.1.32 Tailoring screening tests . 22
6.1.33 Cell matching criteria . 22
6.1.34 Contamination control . 23
[4]
6.1.35 Test data trending . 23
[5]
6.1.36 Flight verification acceptance testing . 23
[8]
6.1.37 Assurance of the life estimation . 23
6.1.38 Parameter measurement tolerances . 23
[5][15]
6.1.39 Battery testing .24
[4][15]
6.1.40 Development testing .24
6.1.41 Charge control testing .24
6.1.42 Thermal control testing .24
6.1.43 Mechanical test . 25
[4]
6.1.44 Qualification test . 25
6.1.45 Qualification test levels and duration . 25
6.1.46 In-process inspections and tests . 25
6.1.47 Data collection and acquisition rates . 25
6.2 Safety. 26
6.2.1 General . 26
6.2.2 Definitions of dangerous phenomenon .27
6.2.3 Technical requirement .27
6.2.4 Fault tolerance .27
[5]
6.2.5 Hazard controls . 28
6.2.6 Over-current prevention . 28
6.2.7 Over-voltage protection . 28
6.2.8 Temperature/current management . 28
6.2.9 Insulation and wiring . 28
6.2.10 Positive protection against accidental shorting. 29
6.2.11 Venting . . 29
6.2.12 Crew touch temperature requirements . 29
6.2.13 Terminal contacts . 29
6.2.14 Safety testing . 29
6.2.15 Important test considerations . 30
6.2.16 Thermal runaway propagation .31
6.2.17 Special provision .31
6.2.18 Description for necessary information for system safety review .31
6.3 Logistics . .32
6.3.1 General .32
6.3.2 Manufacture/assembly storage and testing .32

iv
6.3.3 Safety measure for handling . 33
6.3.4 Transportation . 33
7 Battery onboard space vehicle.33
7.1 Performance . 33
7.1.1 General . 33
7.1.2 Basic design . 34
7.1.3 Electrical ground bonding . 34
7.1.4 Temperature reference point of battery module . 34
7.1.5 Preparation for handling, transportation . 34
7.2 Safety. 35
7.2.1 General . 35
7.2.2 Definitions of dangerous phenomenon . 35
7.2.3 Technical requirement . 35
7.3 Logistics . . 35
7.3.1 General . 35
7.3.2 Safety measure for handling . 35
7.3.3 Integration to the space vehicle . 36
7.3.4 Battery maintenance on the space vehicle . 36
7.3.5 Battery transportation equipped in space vehicle . 36
8 Launch site . .37
8.1 General .37
8.2 Performance .37
8.3 Safety.37
8.4 Logistics . . 38
8.4.1 General . 38
8.4.2 Safety measure for handling . 38
8.4.3 Preparation for transportation . 38
8.4.4 SOC level for transportation . 38
8.4.5 Container for transportation. 38
8.4.6 Battery testing (health checking after transportation) . 38
8.4.7 Inspection . 39
8.4.8 State of health verification . 39
8.4.9 Battery storage at launch site . 39
8.4.10 Self-discharge rate . 39
8.4.11 Protection under integration . 40
8.4.12 Handling plate. 40
8.4.13 Electrical connection . 40
8.4.14 Electrical checkout . 40
8.4.15 Battery monitoring . 40
8.4.16 Battery monitoring preceding launch . 40
9 Mission in orbit and end of life .40
Annex A (informative) Parameter measurement tolerances .42
Annex B (informative) Example of cell qualification test .43
Annex C (informative) Hazard identification method .45
Annex D (normative) Safety measure for handling . 47
Annex E (informative) Transportation .49
Annex F (informative) Lot assessment of COTS cells .53
Bibliography .55

v
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out through
ISO technical committees. Each member body interested in a subject for which a technical committee
has been established has the right to be represented on that committee. International organizations,
governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely
with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are described
in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the different types
of ISO document should be noted. This document was drafted in accordance with the editorial rules of the
ISO/IEC Directives, Part 2 (see www.iso.org/directives).
ISO draws attention to the possibility that the implementation of this document may involve the use of (a)
patent(s). ISO takes no position concerning the evidence, validity or applicability of any claimed patent
rights in respect thereof. As of the date of publication of this document, ISO had not received notice of (a)
patent(s) which may be required to implement this document. However, implementers are cautioned that
this may not represent the latest information, which may be obtained from the patent database available at
www.iso.org/patents. ISO shall not be held responsible for identifying any or all such patent rights.
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and expressions
related to conformity assessment, as well as information about ISO's adherence to the World Trade
Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www.iso.org/iso/foreword.html.
This document was prepared by Technical Committee ISO/TC 20, Aircraft and space vehicles, Subcommittee
SC 14, Space systems and operations.
This second edition cancels and replaces the first edition (ISO 17546:2016), which has been technically
revised.
The main changes are as follows:
— updated 5.4 and Annex F.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www.iso.org/members.html.

vi
Introduction
This document has been developed for the purpose of establishing the standard to obtain sustainable
development and to prevent incidents of lithium-ion battery for space vehicles.
Lithium-ion batteries belong to the category of rechargeable batteries which are based on electrochemical
systems. The batteries generally consist of lithium metal oxide for positive electrodes and carbon for
negative electrodes. Lithium element exists in an ionic or quasi-atomic form within a lattice structure of
each electrode material.
For battery developers and spacecraft system architects, this document leads the way to assessing the whole
life cycle from electrolyte filling to the end of the mission in space and to clarify what is considered in the
battery design phase and the processes to reach the appropriate verification.
It is important to prevent lithium-ion batteries (LIB) for space vehicles from having performance defects
in orbit and incidents through the life cycle. The total life cycle of lithium-ion batteries consists of material
manufacturing to deorbit after mission completion as shown in Figure 1.
Since lithium-ion batteries start to deteriorate just after cell activation during cell manufacturing of stage
1, the service life starts at that point. And it continues through cell testing, cell transportation of stage 2,
battery manufacturing/testing of stage 3, battery transportation of stage 4. Eventually, the service life is
regarded defined as the duration until deorbit which corresponds to the end of life of stage 9.
Clauses in this document address “performance”, “safety” and “logistics” according to each stage of the life
cycle, and each requirement belongs to the shelf life of lithium-ion batteries. The shelf life means from cell
activation to launch and does not exceed the shelf life limit. A battery whose shelf life exceeds the shelf life
limit is judged to be non-conforming even if it is not used because the battery capacity is insufficient for the
mission completion. In other words, the shell life is the period until launch while maintaining the battery
capacity to complete required missions.
— Performance
Since LIB starts to degrade from activation, it is necessary to consider meeting the power requirement
through the mission life; that is, to be unaffected from handling conditions (temperature) and usage
conditions in orbit (temperature, cycle, current or power and depth of discharge). Also, the risk in orbit can
be mitigated based on the life estimation; and with care unexpected degradation can be avoided throughout
the whole life cycle.
— Safety
A complex risk assessment process that is easy to understand is established. The method was agreed
internationally at ISO/IEC and is a traditional method for space use. LIB keeps some amount of the SOC to
avoid significant capacity degradation, so that the specific consideration and care for handling are required
because of potential hazard source. It is well known that LIB has specific risks with higher voltage when
compared to other power sources and no saturation characteristic for over-charge. The important thing
is that the process, which can result in a hazardous situation, does not always immediately result in an
incident. Because of these risks, LIB is considered hazardous at all times. The risk assessment becomes very
important to cover a variety of environments during the handling or use and history of stress.
— Logistics
The most important aspect of assuring battery safety and space quality in transportation is to perform a life
cycle assessment of performance and safety from a broad perspective.
Critical damage includes, for example, the temperature history (especially high uncontrolled temperature
outdoors), shock/vibration, and electrical shorts. Also, to reflect the results of handling or usage, the
measurement should be done. All the personnel with responsibilities for the development, design, and
handling should survey and estimate the influence of their assessment spontaneously to improve the
sustainable development of the space component.

vii
Figure 1 — Definition of life cycle stages of lithium-ion battery for space vehicle

viii
International Standard ISO 17546:2024(en)
Space systems — Lithium ion battery for space vehicles —
Design and verification requirements
1 Scope
This document specifies design and minimum verification requirements for lithium-ion batteries from the
perspectives of performance, safety and logistics.
This document is applicable to battery assemblies for space vehicles and component cells of batteries, which
are critical devices to be harmonized with standards and regulations for other industries. In addition, this
document is applicable to component cells which are not designed for space vehicles but can be used in space.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content constitutes
requirements of this document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
ISO 24113, Space systems — Space debris mitigation requirements
MIL-STD-1686, ELECTROSTATIC DISCHARGE CONTROL PROGRAM FOR PROTECTION OF ELECTRICAL AND
ELECTRONIC PARTS, ASSEMBLIES AND EQUIPMENT (EXCLUDING ELECTRICALLY INITIATED EXPLOSIVE
DEVICES)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— IEC Electropedia: available at https:// www .electropedia .org/
— ISO Online browsing platform: available at https:// www .iso .org/ obp
3.1
activation
process of making an assembled cell (3.4) functional, by introducing an electrolyte at the manufacturing
facility during cell production, which is used to define the start of battery (3.3) shelf life (3.19)
Note 1 to entry: See References [4], [5], [6] and [11].
3.2
aging
permanent loss of capacity due to repeated cycling or passage of time from activation (3.1)
Note 1 to entry: See Reference [6].
3.3
battery
two or more cells (3.4) which are electrically connected together, fitted with devices necessary for use, for
example, case, terminals, marking and protective devices (3.26)
[9]
Note 1 to entry: A single cell battery is considered a “cell” .

Note 2 to entry: A battery may also include some or more attachments, such as electrical bypass devices, charge
[4][5]
control electronics, heaters, temperature sensors, thermal switches, and thermal control elements .
Note 3 to entry: Units that are commonly referred to as “battery packs”, “modules”, or “battery assemblies” having the
primary function of providing a source of power to another piece of equipment are, for the purposes of this document,
[9]
treated as batteries .
3.4
cell
single encased electrochemical unit (one positive and one negative electrode) which exhibits a voltage
differential across its two terminals
Note 1 to entry: See Reference [9].
3.5
COTS cell
cell (3.4) mass-produced for terrestrial use by third parties such as distributors
Note 1 to entry: COTS cells have various kinds of types, 26650, 21700,18650, 17670, 18500, 18350, 17500, 16340,
14500, 10440 of cylindrical shape identified by external dimensions, and rectangular shape in metallic container, and
thin pouch type.
3.6
dangerous phenomenon
phenomenon where a lithium-ion battery (3.20) is damaged
EXAMPLE fire (3.10), bust/explosion (3.8), leakage (3.18) of cell (3.4) electrolyte, venting (3.34), burns from
excessively high external temperatures, rupture (3.28) of battery case with exposure of internal components, and
smokes
3.7
disassembly
vent (3.34) or rupture (3.28) where solid matter from any part of a cell (3.4) or battery (3.3) penetrates a
wire mesh screen (annealed aluminium wire with a diameter of 0,25 mm and grid density of 6 wires per
centimetre to 7 wires per centimetre) placed 25 cm away from the cell or battery
Note 1 to entry: See Reference [9].
3.8
explosion
condition that occurs when a cell (3.4) container or battery (3.3) case violently opens and major components
are forcibly expelled and the cell or battery casing is torn or split
Note 1 to entry: See References [12] and [14].
3.9
external short circuit
direct connection between positive and negative terminals of a cell (3.4) or battery (3.3) that provides less
than 0,1 Ω resistance path for current flow
Note 1 to entry: An external short circuit occurs when a direct connection between the positive and negative terminals
is made where the connection resistance is sufficiently low enough to higher than rated current flow through the cell.
Note 2 to entry: See Reference [9].
3.10
fire
flames emitted from the test cell (3.4) or battery (3.3)
Note 1 to entry: See References [9] and [12].

3.11
out-gassing
evolution of gas from one or more of the electrodes in a cell (3.4)
Note 1 to entry: See Reference [6].
3.12
harm
physical injury or damage to the health of people or damage to property or the environment
3.13
hazard
potential source of harm (3.12)
Note 1 to entry: The term hazard is qualified in order to define its origin or the nature of the expected harm (3.12) (e.g.
electric shock hazard, crushing hazard, cutting hazard, toxic hazard, fire (3.10) hazard, drowning hazard).
3.14
hermeti
...