When In-House CT Isn’t Enough: How to Expand Battery QA Capacity

Quality assurance is the mainstay of battery manufacturing. Growth in EV and energy storage demand is putting pressure on QA. Before being made available to the public, manufacturers validate battery designs, production processes, and sample lots against standardized safety and performance standards. The higher the risk, the more extensive the testing must be. Many manufacturers have adopted the CT scan method for battery inspection to detect defects hidden within the battery. Technicians can locate even the tiniest fractures, voids, or foreign material that may lead to malfunction of the battery at an early stage.

With the growing need for batteries, the capacity of in-house CT systems is often exhausted. Companies may discover that their machines are unable to handle either the quantity or the intricacy of the tests needed for compliance and performance. At that point, the problem shifts to figuring out ways of increasing battery QA potential without causing a drop in the pace of production.

Nel PreTech Corporation is an external provider of industrial CT scanning for batteries. We fill the gaps in battery defect detection with CT using trusted Zeiss equipment like the Metrotom series 800 and 1500 models. Our expertise in battery quality assurance testing with industrial CT scanning and ISO/IEC 17025 accreditation is the most trusted in the business. 

Why CT Scan Battery Inspection Matters

Modern batteries move the world. They power electric vehicles (EVs), small medical devices, consumer electronics, and industrial systems. When failures occur in any of these applications, it can result in safety declines and monetary loss. The use of CT scans to examine the internal structure and ascertain that every unit complies with quality standards is essential for manufacturers.

CT scan cross-section methods have more capabilities than surface inspection or conventional tests can achieve. Through 3D imaging, CT scanning exposes faults that are undetectable by other traditional inspection methods. It gives engineers the confidence of meeting government and industry standards for lithium and non-lithium batteries alike.

The Limits of In-House CT

Many battery manufacturers incorporate in-house CT systems into their workflow. Maintaining direct oversight of quality assurance may be a driving factor. They want complete control of the inspection process or integration into existing R&D and prototyping systems. This approach can be both practical and cost-effective. However, if demand increases, it may not be sustainable.

Limitations emerge when production needs increase. In-house CT systems, while useful, often have built-in constraints that become apparent under pressure:

• Scan Envelope and Resolution Trade-offs – Most in-house CT systems are optimized for a specific range of part sizes. As projects expand or diversify, companies can quickly hit the limits of their machine’s scan envelope or sacrifice resolution to fit larger parts.
  
  
• Throughput Bottlenecks – An in-house CT system running at capacity can quickly become a production bottleneck.
  
  
• Staffing and Expertise – Running computed tomography machines isn’t just about pushing a button. It requires trained technicians, regular calibration intervals, and deep knowledge of reconstruction software and analysis. Without dedicated expertise, the reliability of data may be sub-par.
  
  
• Maintenance and Downtime – Internal machines demand regular maintenance. As equipment ages, repairs increase. Any downtime can disrupt inspection schedules and delay product release.
  
  
• Compliance and Accreditation – Meeting industry-specific standards often requires accredited inspection processes. In-house systems and personnel may not always align with regulatory or certification requirements.

When companies rely exclusively on internal systems, they run the risk of falling behind during spikes in demand or when faced with more complex inspection requirements. For organizations committed to scaling production, partnering with an accredited CT service provider can offer the flexibility, advanced technology, and expertise needed to keep quality assurance robust and reliable.

Expanding QA Capacity

Manufacturers can increase QA capacity through various methods to meet increased demand.

Partner with External CT Providers

Specialized service providers run sophisticated computed tomography (CT) labs that are tailor-made for processing large amounts of data. By collaborating with them, battery manufacturers can transfer a portion of their testing work to third parties. 

What battery defects can CT detect?

• Porosity analysis 
• Weld/joint inspection
• Electrode alignment
• Separator integrity 
• Anode overhang

The solution is effective in times of peak production or when the capacity of the internal systems has been reached. Moreover, it is a simple way of gaining the latest technology without the need for an upfront investment.

Use a Hybrid Model

Another practical battery QA solution would be to maintain an in-house CT scanner for large-volume scans or routine inspections. Use an external service provider for Research & Development and small sample inspections.

Maintaining such a balance guarantees the availability of a certain degree of flexibility. Detailed work and routine tasks can both be accomplished with a CT scanning partnership.

Build a Global Network

Having a distributed network of CT resources is the best way for multinational battery makers to guarantee system stability. Local testing facilities not only minimize shipping times but also allow companies to keep their quality assurance standards at the same level globally.

Strategic Benefits of Expanding QA

Going beyond just in-house CT not only increases capacity but also has a positive effect on the company's ability to maintain competitive advantages in the future.

• Consistency: Scanning can be conducted in different locations using standardized methods.
• Faster product launches: New designs can hit the market faster because there are fewer bottlenecks.
• Risk management: Machine breakdowns will not affect a company as much if there are external partners.
• Customer confidence: Trust in the testing process is established, which leads to customer loyalty.
  
  

Moving Forward with Battery CT Inspections 

The increasing use of electric vehicles and energy storage has made the quality of batteries a high priority. In-house CT, while very valuable, often does not satisfy the compliance and performance requirements of some production facilities. By using external partners, technology that can be scaled, or hybrid models to open up QA capacity, battery manufacturers can accelerate production timelines.

A CT strategy that blends in-house resources with external expertise provides both strength and flexibility. This approach helps manufacturers maintain compliance with the highest industry standards, minimize production interruptions, and build a competitive edge in the global market through consistent, trustworthy results.

Contact Nel PreTech if you’d like to outsource CT battery inspection.