CT Scanning EV Batteries: How Micro-Defects Today Become Recalls Tomorrow

The demand for EV batteries is increasing significantly, driven by the growing demand for electric vehicles (EVs). Battery manufacturers continually research and refine the battery manufacturing process to optimize performance and durability while reducing costs.

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Besides making EV batteries durable and cost-effective, manufacturers are also trying to detect and eliminate micro-defects of batteries to prevent recalls. The industrial CT scanner is a powerful tool that helps manufacturers identify micro-defects through EV battery inspection. In this article, we’ll explore examples of micro-defects and the role industrial CT scanning plays in uncovering them. 

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What Micro Defects Can Industrial CT Scanning Detect in EV Batteries?

A minor fault in EV batteries can cause significant recalls in the future. If any inclusion or impurities are added to the materials during the manufacturing process of batteries, it may cause immediate or future damage to the battery or a safety risk to the user. Two widely recognized EV manufacturers had to recall popular models in 2021 due to defects in battery cells, which could lead to overheating and fire risk. General Motors (GM) had to recall the Chevy Bolt EV and EUV, which cost LG Energy Solutions about $1.8 billion. Hyundai recalled 82,000 electric vehicles worldwide, including the Kona Electric and Ioniq Electric models. This recall was a $400 million loss due to a battery defect. Micro-defects can occur at any stage of manufacturing EV batteries. Industrial CT scanning services can support R&D, failure analysis, and end-of-life recycling studies.

Defects Detected by Battery CT Scanning

• Defects in the internal cell
• Impurities in materials or foreign material inclusions
• Electrode alignment or electrode delamination
• Over-voltage during formation cycle (first time cells are charged)
• Weld voids in cell tabs
• Cracked casings
• Separator damage

What Issues Can Battery Defects Cause?

• Charge/discharge capacity loss and shorter driving ranges
• Lower efficiency and excess heat
• Module or pack uneven charge/discharge, reducing overall performance
• Accelerated degradation
• Cycle life reduction
• Idle self-discharge
• Thermal runaway
• Electrical shorts
• Pouch cell bulging, leakage, or rupture
• Release of flammable or corrosive electrolytes
• Structural weakness leading to fire risk during impact events
• Scrap rate increase of expensive materials
• Expensive recalls
• Customer dissatisfaction, warranty claims, and financial loss

To learn more about battery scanning, download our battery brochure.

How Does Battery CT Scanning Reduce Recall Risks?

EV battery recall prevention requires non-destructive, high-resolution analysis to catch problems before they escalate. For regulated industries, industrial CT scanning labs like Nel PreTech Corporation are accredited to ISO/IEC 17025 for accurate and traceable inspection and interrogation of EV batteries at every stage of the battery lifecycle.

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Manufacturing 

During production, CT scanning verifies cell and module integrity. Industrial CT scanning services can detect and highlight every minor defect or impurity that manual or traditional inspection will miss. Identifying and addressing these problems during assembly or formation cycling prevents them from compounding into large-scale failures that can trigger recalls.

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First Article Inspection

Because batteries are the most expensive component in an EV, early validation is critical. First article inspection with CT scanning provides detailed 3D images of internal structures, exposing irregularities during initial production runs. Manufacturers can refine processes before scaling up, reducing the risk of costly scrap, rework, or full production recalls.

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Testing & Quality Assurance

Even with careful manufacturing, latent defects can emerge. Industrial CT scanning supports ongoing testing and quality assurance by pinpointing root causes. These insights enable engineers to strengthen materials, refine assembly processes, and validate long-term durability. Engineers use industrial CT scanning to ensure their EV batteries meet both performance expectations and safety regulations.

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EV Battery Future

Studies show that by 2030, 45% of total vehicles will be EVs. This speculation also reveals that the demand and manufacturing of EV batteries will increase. Engineers continue to improve the manufacturing process to provide more durable, safe, and cost-effective EV batteries. Industrial CT scanning for EV batteries reduces financial risk by detecting defects before they escalate into costly recalls.

Partnering with Nel PreTech for accredited industrial CT scanning will help with early detection of critical micro-defects. Safeguard your EV battery production against recalls, financial loss, and brand reputation. Contact us today for a consultation or free quote.