Meet the Fusion Series: The First Fully Integrated Battery Test System

Battery innovation is moving fast. From EV packs to wearable electronics, researchers and manufacturers need reliable testing solutions that keep pace with new designs. But too often, testing programs get bogged down in integration delays, configuring environmental chambers, cyclers, fixtures, and safety systems from multiple vendors before a single test can begin.

That’s why Associated Environmental Systems (AES) and MACCOR developed FUSION, the first fully integrated battery test system.

Why Integration Matters

Traditional battery testing setups require multiple purchase orders, weeks of on-site integration, and extensive troubleshooting to get chambers and cyclers communicating together. These challenges can stall projects, stretch budgets, and slow product launches.

By uniting environmental chambers, battery cyclers, fixtures, and safety systems into a single pre-engineered platform, FUSION eliminates integration headaches. Every system ships assembled, validated, and ready to test, so teams can start testing immediately. 

Built Together: AES × MACCOR

AES and MACCOR aren’t just vendors working in parallel, they’ve been partnering for over a decade to deliver complete solutions to battery developers worldwide.

Now that collaboration is built into every FUSION unit. Customers benefit from:

• Single purchase order – one system, one delivery, one support team
• Unified controls – AESONE CONNECT® and MACCOR's software work seamlessly together
• Proven reliability – platforms trusted by leading manufacturers and research labs across industries

Scalable Configurations for Every Application

Whether you’re developing consumer cells or validating high-power EV packs, FUSION offers a configuration that matches your testing goals today and grows with your needs tomorrow.

• FUSION-24-03-3200
  Dual-chamber system for maximum throughput
  • 200-400A per channel, scalable to 16 channels
  • Two 12 cu-ft battery safety chambers
  • Up to 90% return-to-grid efficiency
  • Ideal for EV packs, aerospace modules, and stationary storage

• FUSION-12-016-1600
  High-power testing in a compact footprint
  • 200-400A per channel, scalable to 8 channels
  • Single 12 cu-ft SC-512-4-SAFE chamber
  • Perfect for pilot lines and automotive module validation

• FUSION-08-192-0192
  Ultra-dense channel system for high-volume testing
  • 192 channels at 1A max current each
  • Four current ranges down to 5µA
  • Fast rise times for precise consumer cell and wearable R&D

• FUSION-08-064-0960
  Flexible mid-range system
  • 64 channels at 15A max current each
  • Four current ranges down to 30µA
  • Suited for small-cell development and compact module testing

Designed for Speed, Safety, and Accuracy

Every FUSION system includes:

• AES environmental chambers with precise temperature control
• MACCOR battery cyclers with microamp-to-megawatt range capabilities
• Integrated fixtures and pre-wired interconnects
• Unified software for data acquisition and monitoring
• Built-in safety systems validated to meet global test standards

FUSION enables accurate, sustainable validation for even the most demanding applications.

Accelerating Innovation

Battery research can’t afford downtime. By removing integration delays, FUSION lets teams dedicate resources to testing and innovation—not troubleshooting.

From coin cells to full EV packs, from consumer devices to aerospace systems, FUSION provides a ready-to-run platform that scales with your requirements and delivers confidence with every test.

Contact us today to craft the perfect battery test set up for your unique testing requirements.