Associated Environmental Systems (AES) and MACCOR Inc. have announced FUSION, a fully integrated battery test system. FUSION combines environmental chambers, battery test fixtures, and battery cyclers in a single pre-configured solution, eliminating integration delays and giving developers a faster, more reliable way to validate and improve battery performance.
Manufactured in the US, FUSION reflects AES and Maccor’s commitment to quality, customer confidence, and constant innovation.
Battery testing demands outpace integration capabilities
Battery testing demand is accelerating across electric vehicles, consumer electronics, aerospace, military and defense, and energy storage. Laboratories and manufacturers are under pressure to validate more cells, modules, and packs in less time to keep pace with innovation.
Yet traditional test setups slow progress. Teams often juggle multiple vendors, separate purchase orders, and weeks of on-site integration to have chambers and cyclers communicate. Compatibility troubleshooting and custom programming can stretch deployments from days into months, delaying critical product development timelines. FUSION solves these challenges by providing everything in one fully compatible module that is ready for immediate use.
A complete integrated battery testing solution
FUSION is more than a chamber and a cycler in the same crate. It’s a fully engineered system where hardware, wiring, safety, and controls are designed, validated, and tested to operate as one. This pre-engineered approach gives customers confidence that their system will work seamlessly before it arrives on site.
Each FUSION unit includes:
- Maccor battery cyclers
- AES environmental chambers
- Integrated safety systems within the chamber
- Pre-wired cables and wiring
- Battery fixtures matched to cell formats
- Unified control software – AESONE CONNECT and Maccor Software Suite
“Customers can issue a single purchase order and receive a complete, turnkey product,” said Mike Sandoval, VP of Business Development at Maccor. “This approach simplifies procurement, accelerates setup, and reduces risk. It gives customers a faster path to reliable test results.”
With integration already solved, customers can accelerate testing programs at scale, redirecting resources toward innovation instead of troubleshooting. From coin cells to EV pack validation, FUSION helps teams focus on results rather than system setup.
“Customers consistently tell us their biggest frustration is making different systems communicate,” added Aaron Robinson, VP of Sales and Service at AES. “With FUSION, the controls are already integrated and work together immediately.”
Technical capabilities:
FUSION is available in four configurations to meet a range of testing needs:
- FUSION-24-016-3200: 200-400A per channel, scalable to 16 channels
- FUSION-12-008-1600: 200-400A per channel, scalable to 8 channels
- FUSION-08-192-0192: 192 channels at 1A max current each
- FUSION-08-064-0960: 64 channels at 15A max current each
The FUSION series has a temperature range from -20° to +80° C and delivers ±0.5° C stability and up to 90% return-to-grid efficiency for regenerative testing on the higher amperage solutions.
Such integration requires extensive experience in environmental chamber design and battery cycler engineering. AES has manufactured environmental chambers since 1959, deploying more than 200,000 testing channels. Maccor, the world’s largest battery test system manufacturer, serves over 1,500 customers in over 50 countries.
Such integration requires deep experience in both environmental chamber design and battery cycler engineering. AES has been manufacturing environmental chambers since 1959, deploying more than 200,000 testing channels worldwide. Maccor, the largest global supplier of battery test systems, supports more than 1,500 customers across 50 countries.
The FUSION platform builds on more than a decade of collaborative installations between the two US-based companies.
Filed Under: Batteries, Technology News