A product can pass every room-temperature functional check and still fail the first time it is started at −40°C.
The failure is not always dramatic. A display may respond more slowly, a battery may deliver less usable power, a relay may switch less reliably, or a seal may lose flexibility after the entire assembly has cooled down.
That is what low temperature testing is designed to uncover.
For electronics, automotive parts, batteries, aerospace equipment and materials, a reliable cold test is not simply a matter of setting a chamber to the lowest possible temperature. Engineers also need to define how the specimen will be used, whether it is powered, how long it must remain at temperature, how stabilization is determined and what performance is measured.
This guide explains the main low temperature test methods, common applications, important standards and the equipment used to reproduce controlled cold environments in the laboratory.
What Is Low Temperature Testing?
Low temperature testing exposes a product, component or material to a controlled cold environment to evaluate whether it can operate, survive storage or maintain specified performance under defined temperature conditions.
Depending on the product, the test may be designed to answer very different questions:
- Will the product still start at −40°C?
- Can it survive several hours of cold storage?
- Does battery performance fall outside the required range?
- Does a material become brittle?
- Will a connector, relay or sensor continue to function?
- Does performance recover after the specimen returns to room temperature?
A typical low temperature test may follow this sequence:
Initial Inspection
↓
Load Specimen
↓
Cool to Target Temperature
↓
Allow Specimen to Stabilize
↓
Maintain the Required Exposure
↓
Operate / Measure / Inspect
↓
Recovery
↓
Final Evaluation
The chamber creates the environment, but the test requirement must define what happens inside that environment.
What Actually Changes at Low Temperature?
Cold conditions affect materials and assemblies in different ways.
For electronics, the first sign of trouble is often functional rather than visible. A display may become sluggish, a relay may switch inconsistently, or a sensor may begin to drift. Connectors and soldered assemblies can also respond to dimensional changes as materials contract.
Batteries introduce another set of concerns. At low temperature, available capacity and discharge capability may decrease, voltage behavior can change, and charging performance may become more limited. This is one reason portable electronics and electric vehicle systems require careful cold-weather evaluation.
Plastics, rubber and elastomers may become harder or less flexible. A housing that survives an impact test at room temperature may crack more easily after cold conditioning. A seal may contract enough to change sealing performance even though no visible damage appears.
Mechanical assemblies can also behave differently. Lubricants become more viscous, clearances change, and different materials contract at different rates. A product made from plastic, metal, rubber and adhesives may therefore show problems that would never appear if each material were evaluated separately.
The important point is that a low temperature test does not look for only one kind of failure.
It looks for temperature-dependent behavior.
Low Temperature Operating Test vs Storage Test
One of the first decisions is whether the specimen must operate in the cold or simply survive the cold.
Those are different requirements.
Low Temperature Operating Test
In an operating test, the specimen must function while exposed to the specified low-temperature condition.
Typical examples include:
- starting an automotive ECU;
- checking a display;
- operating a smartphone;
- measuring sensor output;
- running an industrial controller;
- evaluating communication equipment.
A typical sequence is:
Room Temperature
→
Cooling
→
Stabilization
→
POWER ON
→
Functional Measurement
For automotive electronics, the engineering question is often not:
Can the ECU survive −40°C?
It is:
Can the ECU start, communicate and respond correctly after sitting at −40°C long enough for the entire unit to cool down?
That is a more demanding requirement.
Low Temperature Storage Test
In a storage test, the specimen is generally exposed in a non-operating condition.
The test may simulate:
- transportation;
- warehousing;
- winter storage;
- cold climate exposure;
- storage of components or spare parts.
A typical process is:
Initial Inspection
→
Cold Exposure
→
Dwell
→
Recovery
→
Inspection / Functional Check
A product that survives low-temperature storage does not automatically prove that it can operate normally at the same temperature.
That distinction should be clear before the chamber program is written.
IEC 60068-2-1 and Cold Testing
IEC 60068-2-1 is one of the main environmental test standards used for cold testing.
It is intended to evaluate components, equipment and other articles that may be used, transported or stored under low-temperature conditions.
The test setup may vary depending on whether the specimen is:
- heat-dissipating or non-heat-dissipating;
- energized or non-energized;
- packed or unpacked.
These details matter.
A powered control unit may generate enough internal heat that the chamber air reaches −40°C while parts of the electronics remain warmer.
A packaged specimen may also cool much more slowly than the same product tested without packaging.
That means the chamber setpoint alone does not define the actual thermal condition of the specimen.
Low Temperature Testing Is Not the Same as Temperature Cycling
This is one of the most common misunderstandings when environmental equipment is selected.
A specification may include both −40°C and +85°C, but that does not tell you which chamber type is required.
The key question is:
What stress is the test trying to reproduce?
| Test Method | Main Purpose | Typical Temperature Behavior | Typical Equipment |
|---|---|---|---|
| Low Temperature Test | Evaluate cold resistance | Cool → Hold | High & Low Temperature Chamber |
| Temperature Cycling | Evaluate repeated thermal stress | Hot ↔ Cold repeatedly | Environmental / Climate Chamber |
| Rapid Temperature Change | Evaluate controlled fast transitions | Defined °C/min | Rapid Thermal Cycle Chamber |
| Thermal Shock | Evaluate sudden thermal stress | Rapid Hot ⇄ Cold transfer | Thermal Shock Chamber |
Low Temperature Test
A standard cold exposure might look like:
+23°C
↓
−40°C
↓
HOLD
↓
Recovery
The important condition is the cold exposure itself.
Temperature Cycling
A cycling program repeatedly moves between high and low temperatures:
−40°C
↓
+85°C
↓
−40°C
↓
+85°C
This produces repeated expansion and contraction.
It can reveal:
- solder joint problems;
- interface stress;
- seal failure;
- material mismatch;
- assembly fatigue.
Rapid Temperature Change
If the specification defines a controlled rate such as °C/min, transition speed becomes part of the test.
At that point, the question is no longer simply:
How low can the chamber go?
It becomes:
Can the chamber move the loaded specimen between the required temperatures at the specified rate?
This is particularly relevant to automotive electronics, PCB assemblies, sensors and semiconductor reliability testing.
Thermal Shock
Thermal shock creates a much more abrupt temperature transition.
A simplified test looks like:
HOT
↓
Rapid Transfer
↓
COLD
↓
Rapid Transfer
↓
HOT
The purpose is to expose weaknesses caused by sudden thermal expansion and contraction.
The cold-side temperature may be similar to a conventional low temperature test, but the stress mechanism is completely different.
Where Is Low Temperature Testing Used?
Low temperature testing is used anywhere a product may encounter cold conditions during operation, storage or transportation.
The failure mode, however, changes significantly by industry.
| Industry | Typical Products | What Engineers Usually Check |
| Consumer Electronics | Smartphone, tablet, laptop, wearable | Startup, display, battery |
| Automotive | ECU, ADAS, sensor, display | Cold start, communication |
| Battery & Energy | Cell, module, pack, BMS | Voltage, capacity, discharge |
| Electronic Components | PCB, relay, connector, IC | Electrical stability |
| Aerospace | Avionics, sensor, control module | Cold + altitude performance |
| Telecom | Outdoor communication equipment | Startup, communication |
| Industrial | PLC, controller, power supply | Functional stability |
| Materials | Plastic, rubber, cable | Brittleness, flexibility |
Consumer Electronics
A smartphone cold test is rarely just a battery test or a display test.
The battery, touchscreen, camera module, display, adhesives, housing and connectors are all exposed at the same time.
One subsystem may recover immediately after warming while another may show intermittent or permanent degradation.
Typical products include:
- smartphones;
- tablets;
- laptops;
- smartwatches;
- TWS earbuds;
- cameras;
- displays;
- chargers;
- IoT devices.
For these products, engineers usually care about whether the device can start, respond and continue functioning—not simply whether it survives the exposure.
Automotive and EV Electronics
Automotive cold testing often focuses on startup and operation after a cold soak.
Typical specimens include:
- ECUs;
- ADAS modules;
- sensors;
- automotive cameras;
- radar units;
- displays;
- instrument clusters;
- BMS units;
- power electronics;
- connectors.
A component can pass a storage test and still fail a cold-start functional check.
That is why powered testing is particularly important in automotive qualification.
Batteries and Energy Storage
Typical specimens include:
- lithium-ion cells;
- battery modules;
- small battery packs;
- EV battery components;
- energy storage components;
- BMS units.
At low temperatures, engineers may monitor:
- voltage;
- capacity;
- internal resistance;
- current;
- discharge behavior;
- functional response.
Battery testing also introduces a second question:
Does the specimen require enhanced chamber safety protection?
Routine environmental conditioning and higher-risk battery testing should not automatically be treated as the same application.
Electronic Components and Semiconductor
For electronic components, low-temperature testing can expose subtle changes before complete failure occurs.
Typical products include:
- PCB and PCBA;
- IC packages;
- relays;
- switches;
- capacitors;
- sensors;
- connectors;
- power modules.
The objective may be to measure electrical stability, switching behavior, contact performance or package integrity under cold conditions.
Aerospace and Aviation
Aerospace applications often combine temperature with another environmental factor: altitude.
Avionics, sensors, communication modules and control electronics may need to operate at low temperature while also exposed to reduced atmospheric pressure.
In that case, a conventional temperature chamber is not enough.
The test condition becomes:
Low Temperature
Low Air Pressure
Telecommunications and Industrial Equipment
Outdoor communication and industrial equipment may remain in cold environments for long periods before being required to operate immediately.
Typical specimens include:
- base station electronics;
- routers;
- optical modules;
- PLCs;
- industrial controllers;
- power supplies;
- outdoor sensors;
- relays.
The practical question is simple:
After sitting in the cold, does the product still start and operate correctly?
Plastics, Rubber, Cables and Other Materials
For materials, cold conditioning is often only the first half of the test.
The actual result may come from:
- tensile testing;
- bending;
- impact;
- peel;
- compression;
- tearing.
For example, a cable jacket may look unchanged after cold exposure but show significantly reduced flexibility during a bend test.
Likewise, a plastic part may appear visually intact but become much more brittle under impact or mechanical load.
How Should Test Temperature and Duration Be Defined?
There is no universal low-temperature value for every product.
Laboratory programs may use temperatures such as:
| Temperature | Typical Test Context |
| 0°C | Mild cold exposure |
| −10°C | Transportation or consumer applications |
| −20°C | Electronics and storage |
| −30°C | Outdoor products |
| −40°C | Automotive, industrial and electronics |
| −55°C | Severe environmental conditions |
| −65°C / −70°C | Specialized applications |
These are examples, not default test conditions.
The correct temperature should come from:
- the applicable standard;
- product specification;
- customer requirement;
- intended service environment.
This leads to one of the most common purchasing mistakes:
Buying the chamber with the lowest possible temperature instead of the chamber that best matches the actual test.
If your requirement is −40°C, a −70°C chamber is not automatically the better choice.
Cooling capacity, uniformity, working volume, load condition and transition performance may matter more.
Chamber Air Temperature Is Not Specimen Temperature
This is one of the easiest ways to create a technically correct chamber program but a misleading test result.
A controller showing −40°C only tells you what the chamber control sensor sees.
It does not prove that:
- a 20 kg battery module;
- a packaged assembly;
- a dense metal component;
- or a powered electronic unit
has reached −40°C internally.
Specimen temperature depends on:
- mass;
- material;
- geometry;
- packaging;
- airflow;
- specimen spacing;
- internal heat generation;
- sensor location.
A lightweight PCB may approach chamber temperature relatively quickly.
A large battery module may require much longer.
So the test sequence should be understood as:
Chamber Setpoint
↓
Air Stabilization
↓
Specimen Stabilization
↓
Start Defined Dwell
This distinction matters far more for large or heat-generating specimens than for small passive components.
Powered Specimens, Heat Load and Chamber Loading
A chamber may reach −40°C easily when empty and behave very differently when several powered specimens are running inside.
That is why temperature range alone is not enough for equipment selection.
Powered Specimens
Operating electronics generate heat.
This heat becomes part of the chamber load:
Electrical Power
↓
Heat Generated by Specimen
↓
Additional Cooling Requirement
For powered tests, engineers should consider:
- specimen heat dissipation;
- number of units;
- refrigeration capacity;
- airflow;
- cable ports;
- electrical feedthroughs.
A controller, power supply or automotive module that dissipates heat continuously may remain warmer internally than the surrounding chamber air.
Chamber Loading
The same issue applies to physical loading.
A chamber should not be treated as a cold storage cabinet that can be completely filled.
Poor loading can:
- restrict airflow;
- increase stabilization time;
- create temperature gradients;
- reduce temperature uniformity;
- affect cooling performance.
The relevant question is not only:
What is the chamber volume?
It is also:
How much usable test space remains after the specimens are installed with enough airflow clearance?
A 408 L chamber does not mean 408 L of specimen volume should be packed inside.
How to Select Low Temperature Testing Equipment
Equipment selection should begin with the specimen and the test method.
Not with the catalog.
Step 1 — Define the Specimen
Record:
- product type;
- dimensions;
- weight;
- quantity;
- packaging condition;
- material.
For powered products, estimate heat generation as well.
Step 2 — Define the Test Purpose
Is the requirement:
- cold storage?
- cold operation?
- low-temperature conditioning?
- temperature cycling?
- rapid temperature change?
- thermal shock?
- temperature and humidity?
- temperature and altitude?
- mechanical testing under low temperature?
This one decision eliminates many unsuitable chamber types.
Step 3 — Define the Temperature Requirement
Specify the actual:
Minimum Temperature
and
Maximum Temperature
Do not select a −70°C system automatically if the test never goes below −40°C.
Step 4 — Define Chamber Size
Use:
Specimen Size
Quantity
Airflow Clearance
not specimen dimensions alone.
Step 5 — Estimate Heat Load
For powered specimens, determine:
- electrical input;
- number of units;
- operating mode;
- expected heat dissipation.
A chamber that performs well when empty may not maintain the same conditions under a large powered load.
Step 6 — Check Additional Environmental Requirements
At this point, ask whether the program also needs:
- humidity;
- controlled rapid ramp rates;
- thermal shock;
- low pressure;
- battery safety protection;
- mechanical loading.
This is where chamber type should be selected.
Which ITM-LAB Equipment Fits Each Low Temperature Test?
Rather than choosing by model name first, it is easier to select equipment from the required test condition.
When Standard Cold Exposure Is Enough
If the requirement is mainly:
- cold storage;
- low-temperature operation;
- high/low temperature exposure;
then a GDW High & Low Temperature Test Chamber is the most direct option.
Typical applications include:
- electronics;
- automotive parts;
- electrical products;
- plastics;
- rubber;
- general components.
A typical program may look like:
23°C
→
−40°C
→
Stabilize
→
Dwell
→
Evaluate
When Humidity Is Also Part of the Program
If the laboratory must perform both temperature and climate testing, a GDJS Temperature & Humidity Test Chamber is more suitable.
This is common when one laboratory needs to support:
- low temperature;
- high temperature;
- damp heat;
- temperature-humidity programs.
Typical users include electronics, automotive, semiconductor and component laboratories.
The key reason to choose GDJS is not simply that it can reach low temperature.
It is that the overall test program includes humidity as well as temperature.
When Transition Speed Matters
If the test specifies a defined temperature change rate, a standard cold chamber is no longer the correct comparison.
A KTB Rapid Rate Thermal Cycle Chamber is designed for situations where the transition itself becomes part of the test.
Typical applications include:
- automotive electronics;
- PCB assemblies;
- sensors;
- semiconductor devices;
- control modules.
The selection question changes from:
How low can the chamber go?
to:
How quickly can it move the loaded specimen between the required temperatures?
When the Test Is Thermal Shock
If the specimen must move rapidly between extreme hot and cold conditions, the requirement points toward a CTS Thermal Shock Chamber.
Typical applications include:
- electronic components;
- semiconductor packages;
- automotive electronics;
- high-reliability materials.
The cold-side temperature may look similar to a normal low-temperature test, but the equipment and test stress are different.
When Low Temperature Must Be Combined with Altitude
For aerospace, aviation and high-altitude electronics, temperature may need to be evaluated together with reduced atmospheric pressure.
That is where GDJZ Temperature + Low Air Pressure Chamber becomes relevant.
The test condition is:
LOW TEMPERATURE
LOW AIR PRESSURE
This cannot be reproduced by a conventional temperature chamber alone.
When Battery Testing Requires Additional Protection
Battery specimens may require enhanced chamber protection depending on the test and risk level.
An ITM-DEP Explosion-Proof High & Low Temperature Chamber is more appropriate when environmental testing must be combined with additional safety measures.
Possible applications include battery cells, modules and packs where the risk assessment requires stronger chamber protection.
When Mechanical Properties Must Be Measured in the Cold
Some applications are not looking for a functional pass/fail result.
They need to know:
How much does strength, flexibility or adhesion change at low temperature?
In that case, RS-8000GDW High & Low Temperature Universal Testing Machine is a different type of solution.
Typical tests include:
- tensile;
- compression;
- bending;
- peel;
- shear;
- tearing.
Typical materials include:
- plastics;
- rubber;
- metals;
- cable materials;
- textiles;
- composites.
Low Temperature Test Equipment Selection Guide
| Test Requirement | Suitable Equipment Type | ITM-LAB Series |
| Standard Cold Exposure | High & Low Temperature Chamber | GDW |
| Temperature + Humidity | Climate Chamber | GDJS |
| Rapid Temperature Change | Rapid Thermal Cycle Chamber | KTB |
| Thermal Shock | Thermal Shock Chamber | CTS |
| Temperature + Altitude | Temperature & Low Pressure Chamber | GDJZ |
| Battery Test with Enhanced Protection | Explosion-Proof Temperature Chamber | ITM-DEP |
| Mechanical Testing at Low Temperature | Temperature UTM | RS-8000GDW |
The simplest rule is:
Define the test first. Select the chamber second.
Common Low Temperature Test Setup Mistakes
1. Selecting Equipment Only by Minimum Temperature
A lower minimum temperature does not automatically mean better performance for the actual test.
The chamber must also suit:
- load;
- volume;
- cooling requirement;
- airflow;
- stability;
- transition rate.
2. Starting the Dwell Too Early
If the chamber air reaches −40°C before the specimen does, starting the dwell immediately may shorten the real cold exposure.
This is especially relevant for large or dense specimens.
3. Ignoring Heat Generated by the Product
Powered electronics can change the chamber load significantly.
If heat dissipation is not considered, the specimen may not experience the intended condition.
4. Overloading the Working Space
Too many specimens or poor spacing can block airflow.
The result may be uneven temperature distribution and longer stabilization time.
5. Confusing Cold Testing with Thermal Shock
Both tests may use −40°C.
That does not make them the same test.
One evaluates cold exposure.
The other evaluates rapid thermal stress.
6. Using Chamber Capability as the Test Requirement
If the chamber can reach −70°C, that does not mean the product should be tested at −70°C.
The test condition must come from an engineering requirement, not from the equipment specification sheet.
What Information Should You Prepare Before Buying?
Before requesting a chamber quotation, define:
- What product will be tested?
- What are the specimen dimensions and weight?
- How many specimens will be tested together?
- What is the required minimum temperature?
- What is the maximum temperature?
- How long is the exposure?
- Will the specimen operate during the test?
- How much heat will it generate?
- Is humidity required?
- Is a temperature change rate specified?
- Is thermal shock required?
- Is reduced pressure required?
- Does the specimen require additional battery safety protection?
- Which standard or customer specification applies?
Providing this information makes it possible to configure the chamber around the test rather than forcing the test around the chamber.
FAQ
What is low temperature testing?
Low temperature testing exposes a product, component or material to controlled cold conditions to evaluate whether it can operate, survive storage or maintain required performance.
What is IEC 60068-2-1?
IEC 60068-2-1 is an environmental testing standard used for cold testing of components, equipment and other articles intended for low-temperature use, transportation or storage.
What temperature is used for low temperature testing?
There is no universal value. Test temperatures may include −20°C, −40°C, −55°C or lower depending on the applicable standard, customer specification and intended environment.
How long should a low temperature test last?
Test duration depends on cooling time, specimen stabilization, required exposure and recovery conditions. The applicable test method should define how these stages are handled.
Does chamber temperature equal specimen temperature?
Not necessarily. Large, packaged or heat-generating specimens can remain warmer than the chamber air for a significant period.
What is the difference between low temperature testing and thermal shock?
Low temperature testing focuses on controlled cold exposure. Thermal shock evaluates the effect of rapid movement between extreme hot and cold conditions.
Can products operate during a low temperature test?
Yes. Many automotive, electronic and industrial tests require powered operation during cold exposure. The specimen heat load must be considered when selecting chamber capacity.
How do I choose a low temperature test chamber?
Start with the specimen, test purpose, temperature range, chamber size, operating condition and heat load. Then determine whether humidity, rapid temperature change, thermal shock, low pressure or enhanced safety protection is required.
Conclusion
Low temperature testing answers a practical engineering question:
Will the product still meet its requirements after it becomes cold?
A reliable answer depends on much more than the chamber's minimum temperature.
The test should be defined in this order:
Specimen
↓
Operating or Storage Requirement
↓
Test Method
↓
Temperature
↓
Stabilization
↓
Exposure Time
↓
Powered or Unpowered
↓
Heat Load
↓
Additional Environmental Conditions
↓
Equipment
For a conventional cold exposure, a GDW high and low temperature chamber may be sufficient.
If the program also requires humidity, controlled rapid transitions, thermal shock, altitude simulation, enhanced battery protection or mechanical testing at low temperature, a different system is more appropriate.
The best starting question is therefore not:
“How low can the chamber go?”
It is:
“What condition does the specimen need to experience, and what exactly must be measured when it gets there?”
That is the basis of a useful and repeatable low temperature test.
