Battery Scanning Study: CT for EV Cells, Modules & Packs—Finding Voids, Weld & Tab Defects

The demand for safer, longer-lasting, and more energy-efficient batteries continues to rise as electric vehicle (EV) production grows worldwide. Ensuring the safety of batteries requires having accurate visibility of internal structures, which cannot be done through traditional inspection methods. This is where EV battery CT scanning has reshaped the industry.

CT technology delivers thorough, non-destructive imaging of EV cells, modules, and full battery packs, helping manufacturers to identify voids, weld difficulties, tab flaws, and structural anomalies before they become performance or safety hazards.

This guide explains how CT scanning enhances battery inspection, why it’s essential for modern EV quality assurance, and how advanced imaging strengthens reliability across the full battery lifecycle.

Understanding the Need for High-Resolution Battery Scanning

Battery​‍​‌‍​‍‌​‍​‌‍​‍‌ manufacturing is a highly complex operation that requires precision in all stages, such as electrode coating, stacking, winding, welding, electrolyte filling, and sealing. Tiny internal inconsistencies can lead to:

• Lower energy density
• Faster degradation
• Reduced safety margins
• Possibility of thermal runaway

The use of industrial CT (computed tomography) for battery scanning is the central quality control measure that stems from this. CT technology generates precise 3D volumetric images; thus, engineers get the opportunity to see the inner parts without opening or damaging the battery. This non-destructive method is the best choice for both R&D and production-scale ​‍​‌‍​‍‌​‍​‌‍​‍‌verification.

What CT Scanning Reveals Inside EV Cells, Modules & Packs

1. Detecting Internal Voids and Material Density Variations

Internal voids or density inconsistencies within electrode coatings or separator layers can significantly reduce battery efficiency and cycle life. CT scanning allows engineers to identify issues such as:

• Air pockets trapped within electrode powders
• Variations in material density
• Uneven or inconsistent material distribution
• Micro-gaps formed during stacking or assembly

These defects disrupt ion flow, create localized resistance, and can eventually lead to hotspots and accelerated degradation.

2. Spotting Battery Defects Before They Become Safety Risks

The​‍​‌‍​‍‌​‍​‌‍​‍‌ phrase "battery defects" refers to various kinds of differences in the structure of the cells. With the help of CT scans, engineers can see the following problems:

• Pouch cells with layers that are not aligned properly
• Electrodes that have cracks or delamination
• Casing that is deformed or has irregular swelling patterns
• Contaminants that are foreign particles

Any one of these components may lead to a decrease in safety, trustworthiness, and heat stability.

3. Weld-Level Insights: Identifying weld defects in Modules and Packs

Laser welding and ultrasonic welding are widely used to join cell terminals, busbars, and structural components within EV modules and packs. However, poor weld quality is one of the leading causes of battery failures. CT scanning provides detailed weld-level visibility, allowing engineers to detect defects such as:

• Inadequate weld penetration
• Weld joints with cracks
• Welded regions with porosity
• Areas where material is missing or broken welds
• Welded layers between which there is fusion

Strong and uniform welds, a requirement for electrically conductive and mechanically strong high-voltage batteries, make CT data very important in weld verification.

4. Tab Integrity Analysis: Detecting tab defects That Affect Performance

Tabs​‍​‌‍​‍‌​‍​‌‍​‍‌ serve as the electrical highways through which the current flows from one cell to the next in a battery module. When tabs are weak or have been put together in a faulty way, the battery may heat up, the current may not be distributed evenly, or there may be shorts inside the battery.

By using CT scanning to examine batteries, it is possible to identify various defects in tabs, such as:

• Misaligned or folded tabs
• Broken or torn edges
• Weld discontinuities on tabs
• Excessive heat damage during tab bonding
• Voids where tabs meet electrodes

The knowledge gained here is very valuable for the company as it helps them to fine-tune their product design and have better command over the manufacturing ​‍​‌‍​‍‌​‍​‌‍​‍‌process.

Why​‍​‌‍​‍‌​‍​‌‍​‍‌ CT Scanning Is Necessary at Every Battery Development Stage

Research & Development

In the R&D period, a team uses CT for analysis of the cell design, confirmation of the use of new materials, and the improvement of manufacturing processes.

Production Quality Control

Through CT scanning, every batch is checked to be in compliance with the most stringent safety standards that are necessary for automotive-grade batteries.

Failure Analysis

When a battery fails, CT scanning gives an accurate 3D representation of its interior structure, enabling engineers to identify the underlying problem without cutting or injuring the device. It is a non-destructive approach that keeps the batteries to be utilized in future research and facilitates proper and evidence-based diagnosis.

Competitive Benchmarking

By comparing battery technologies side by side, companies may improve the performance of their own goods.

Conclusion

As EV adoption accelerates, the demand for higher battery safety, consistency, and reliability continues to rise. EV battery CT scanning has turned out to be a key element due to the fact that it can fully and non-destructively view cells, modules, and packs ensuring that the process can identify the presence of a void, structural defects, weld issues and tab faults long before they can impact performance or become safety concerns.

Advanced CT inspection can help manufacturers, researchers, and automotive suppliers to enhance accuracy, as well as, increase quality control. NPC provides high-resolution visuals and profound knowledge about EV battery systems, making it a reliable partner for achieving today's stringent safety and performance requirements.

By selecting NPC for your next battery scanning project, you will have the much needed clarity, accuracy, and confidence required to create safer and dependable EV battery designs.