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WEBINAR: Unlock the Power of Industrial CT Scanning
See Deeper. Solve Faster. Spend Smarter.
A 1/2 Hour That Could Reshape Your Inspection Strategy
Date: Wed June 18, 2025
Time: 11am Central Time
Location: Live Online Webinar
See Deeper. Solve Faster. Spend Smarter.
A 1/2 Hour That Could Reshape Your Inspection Strategy
Date: Wed June 18, 2025
Time: 11am Central Time
Location: Live Online Webinar
Most battery problems begin below the cell surface before swelling, overheating, power loss, or breakdowns reveal themselves.
What can lurk inside:
Reliability and performance are threatened long before a battery fails in the real world.
With CT scanning, battery manufacturers get a huge advantage.
Sharper insight leads to smarter decisions and better results.
Traditional inspection methods are not sufficient for battery inspections. Surface checks miss the real culprits behind battery failures. Industrial CT scanning changes the game. It captures a true 3D view of everything inside the battery while everything stays intact. Every electrode, layer, and interface can be interrogated.
That matters during failure investigations. Destructive teardown can eliminate critical evidence before engineering teams fully understand what caused the problem. This allows engineers to inspect internal structures layer by layer while preserving the component for additional testing or validation.
Industrial CT scanning systems can evaluate:
Using high-resolution CT scanning, engineers can visualize internal conditions that are otherwise inaccessible through conventional metrology methods.
Many battery-related failures are not caused by a single defect, and therefore, the analysis is not limited to just one category.
Failures develop gradually through manufacturing variation, charging cycles, vibration, thermal stress, material fatigue, environmental exposure, or assembly inconsistencies that compound over time.
Voids within materials, welds, or interfaces can impact conductivity, heat transfer, and structural integrity. Industrial CT scanning allows engineers to identify and quantify internal porosity without damaging the sample.
Electrode stacking inconsistencies can contribute to uneven current distribution, localized heating, or premature degradation. CT scanning allows precise visualization of layer positioning and alignment throughout the battery structure.
Crushed, folded, punctured, or compromised separators can create unstable internal conditions that increase the risk of short circuits or thermal runaway events.
These defects are often difficult to isolate through conventional inspection methods alone.
Mechanical deformation inside a battery can indicate internal gas generation, thermal stress, material degradation, or manufacturing inconsistencies.
Battery tabs, laser welds, ultrasonic welds, and interconnect structures can be inspected for:
Contamination introduced during manufacturing or assembly can create electrical instability and unpredictable field failures.
Following overheating, venting, or catastrophic failure events, CT scanning can help identify collapse zones, structural deformation, internal displacement, and failure propagation patterns.
For engineering teams investigating field returns or validation failures, preserving internal evidence can be critical.
Nel PreTech supports failure analysis and internal inspection for a wide range of battery chemistries and evolving energy storage technologies.
This includes:
As battery technologies continue evolving toward higher energy density, faster charging cycles, lighter materials, and tighter packaging constraints, internal inspection becomes increasingly important.
Small inconsistencies can create outsized downstream problems once products enter real-world operating conditions.
Battery systems are becoming more compact, more energy-dense, and more structurally complex.
That complexity extends beyond traditional lithium-ion designs. Emerging battery technologies often introduce new internal materials, layered structures, interfaces, and assembly methods that require advanced non-destructive analysis techniques to evaluate internal integrity accurately.
As energy density increases, so does the importance of understanding internal integrity.
Industrial CT scanning provides several advantages over traditional sectioning methods:
Preserve the component for additional testing, validation, or legal documentation.
Inspect the entire internal structure instead of isolated cross sections.
Identify potential failure origins earlier in the investigation process.
Capture precise internal geometry and structural conditions.
Maintain permanent digital datasets for reporting, traceability, validation, and comparison.
Accelerate design improvements by identifying hidden manufacturing or assembly issues sooner.
Nel PreTech supports a wide range of industries and battery-related applications.
Evaluate battery cells, modules, and assemblies for:
Inspect compact electronic battery systems used in:
Analyze mission-critical battery systems where reliability and internal integrity are essential.
Inspect battery-powered medical devices and assemblies where internal defects may impact reliability, safety, or compliance.
Use CT scanning to validate production consistency, assembly quality, and manufacturing process improvements.
Battery failure analysis requires more than surface-level imaging.
Analysis projects using high-resolution industrial CT scanning:
Depending on project requirements, CT data can also support engineering reviews, supplier investigations, manufacturing validation, and design optimization initiatives.
Nel PreTech utilizes advanced industrial CT scanning systems capable of capturing highly detailed volumetric data for complex components and assemblies.
Our inspection technologies support:
Detailed CT datasets help engineering and quality teams make faster decisions during product development, supplier validation, manufacturing investigations, and field-return analysis.
The goal is not simply to generate images.
The goal is to understand what the battery is actually doing internally before the next failure occurs.
Battery failure analysis is not only about identifying defects after failure.
It is also about improving future reliability.
The data collected during CT analysis can help engineering teams:
Understanding internal conditions earlier in the product lifecycle can significantly reduce downstream risk.
Nel PreTech delivers advanced metrology and industrial CT scanning services for manufacturers that require deeper visibility into component performance and internal integrity.
Projects often require more than pass/fail inspection data. Accurate internal analysis can help engineering teams identify risk earlier, validate manufacturing quality, and improve long-term product performance.
Key advantages include:
From early-stage development to production failure investigations, Nel PreTech provides the inspection data engineers need to make informed decisions.
Accredited to ISO/IEC 17025 by A2LA, FFL Registered, ITAR Registered & Compliant. NPC offers the kind of quality management system clients can trust.
A2LA Scope & Cert
A major consumer product company struggles to develop, approve, and launch multiple high-level cavitation molds for high-volume production & global distribution.
Computed tomography and value-add services from Nel PreTech.
Client saves $1 million in direct cost and gains $60 million in cash flow four months sooner.
Major grill manufacturer reaches out with malfunctioning glow plugs.
Industrial CT scanning (x-ray material testing) provides digital 3D x-ray images of internal components of the glow plug & finds a wire break inside the heating device.
Client is able to investigate the root cause of the glow plug failure and fix the problem.
Global OEM medical device company needs help developing and launching drug delivery pumps.
CT scanning and value-add services create a turnkey solution to give the client a competitive advantage.
20 new tools in 20 weeks.
When battery reliability, safety, or manufacturing consistency is at stake, hidden internal defects can become costly problems.
A defect missed during validation can become a warranty issue, supplier dispute, delayed launch, or field failure later.
Advanced industrial CT scanning and non-destructive battery analysis help manufacturers, engineers, and quality teams identify internal defects earlier, shorten investigation timelines, and make more confident engineering decisions.
Contact Nel PreTech today to discuss your battery analysis project, request a quote, or learn more about our industrial CT scanning capabilities.
Nel PreTech Corporation
Phone: (708) 429-4887
Website: www.nelpretech.com
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See Deeper. Solve Faster. Spend Smarter.
A 1/2 Hour That Could Reshape Your Inspection Strategy
Date: Wed June 18, 2025
Time: 11am Central Time
Location: Live Online Webinar
