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Accelerate Battery Research, Development, and Production with Tescan Solutions

Deliver reliable insights from advanced analytical workflows that drive progress in energy storage technologies.

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Tescan solutions

Research and Development

Drive battery innovation with advanced analytical workflows that reveal composition from the nanoscale to full-cell architecture. Tescan imaging and analysis solutions correlate morphology with chemical state and phase composition, enable real-time observation of dynamic processes, and provide quantitative mapping of material structures — supporting the development of safer, longer-lasting, and higher-performing batteries.

FIB-SEM with integrated ToF-SIMS exposes electrode formation and solid-state interfaces, while 4D-STEM resolves crystallographic phases and strain at the nanometer scale. In situ micro-CT complements these insights by tracking electrolyte movement and thermal effects in intact cells.

Deliver reliable results accelerate material discovery, guide cell design, and shape the next generation of battery technologies.

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3_Characterization of LFP cathode with 3D FIB-SEM and ToF-SIMS tomography
Raw Materials Optimization

Improve battery performance consistency by ensuring the quality of lithium, nickel, cobalt, and graphite feedstocks. Tescan’s automated mineralogy workflows provide high-throughput characterization to evaluate deposits, refine beneficiation, and reduce variability in electrode manufacturing.

With Tescan TIMA, complex ores are mapped to distinguish similar phases, quantify liberation and grain size, and model associations critical for recovery. These insights support efficient resource use, strengthen battery material analysis, and create more reliable supply chains for lithium-ion production.

Deliver reliable results that improve process control, support battery validation, and optimize raw material utilization across the energy storage lifecycle.

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Raw Materials Optimization
Production and Quality Assurance

Achieve consistent quality in lithium-ion battery manufacturing while preserving sensitive cell structures. Tescan SEM, FIB-SEM, and micro-CT analysis workflows deliver reproducible 2D and 3D insights essential for battery quality assurance, covering active materials, electrodes, separators, and full cells.

Automated SEM analysis and tomography highlight particle variation, separator morphology, electrode material distribution, and porosity, , while non-destructive micro-CT supports battery diagnostics by revealing electrode alignment, anode overhang, and cap integrity in assembled cells.

Enable reliable results that improve yield, validate processes, and accelerate decision-making across the battery production. 
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i1_3D render of Li-ion battery with anode overhangs highlighted
Failure Analysis

Understand battery failure mechanisms under real-world conditions without disrupting fragile internal structures. Tescan FIB-SEM and micro-CT workflows provide multimodal insight into thermal effects, electrode damage, and hidden defects linked to battery degradation.

In situ heating and non-destructive electrolyte visualization reveals gas formation and structural changes in real time, while 3D FIB-SEM tomography supports battery post-mortem analysis by capturing electrode delamination and cracking, particle degradation, and lithium trapping.

Deliver reliable results that strengthen safety testing, inform root cause analysis, and extend battery lifespan.

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Failure Analysis
Recycling

Support sustainable battery production by maximizing recovery of critical materials from spent cells. Tescan’s automated mineralogy workflows deliver particle-level insight into complex black mass mixtures, helping recyclers refine processes, optimize battery recycling workflows, and improve yields.

Tescan TIMA classifies each particle by its chemistry and texture, distinguishing cathode chemistry, quantifying liberation, and identifying graphite, and residual metal foils. These insights refine recovery strategies, reduce waste, and support battery upcycling initiatives.

Deliver reliable results that strengthen circular economy goals, improve process efficiency, and secure a consistent supply of recovered materials for lithium-ion production.

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Recycling

“At Dragonfly Energy, our goal is to deliver a more sustainable and cost-effective Li-ion battery, and these metrics are fundamentally defined by dynamic nanoscale interactions occurring inside the cell. TESCAN’s electron microscopy and micro-CT solutions provide valuable, correlative insights into the behavior of these complex systems which enable the development of our innovative cell chemistries.”

Dr. Denis Phares
CEO at Dragonfly Energy

Quote-Denis-Phares

Tescan Instruments & Technology

Used in This Workflow

Tescan AMBER X 2

Built for advanced battery and materials research, AMBER X 2 integrates high-throughput plasma FIB milling with ultra-high-resolution SEM imaging.

  • High-current Xe plasma FIB: Section large battery electrodes or multilayer stacks quickly and cleanly

  • Correlative multimodal analysis: Combine structural imaging with STEM, R-STEM, and EDS in one workflow

  • Plasma FIB-SEM for large volumes: Ideal for porosity mapping, electrode degradation, and 3D reconstruction

  • Field-free SEM imaging: Achieve high-contrast, low-kV imaging for delicate battery features
AMBER-X2
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Tescan CLARA

Ultra-high-resolution SEM tailored for nanostructure and surface characterization.

  • True UHR SEM imaging: Resolve nanopores and fiber networks in separators and electrode coatings
  • Essence™ software automation: Automate particle sizing, morphology, and statistical analysis of powders
  • Non-destructive workflows: Analyze separator porosity and coating uniformity at the nanoscale
  • Stable low-voltage imaging: Ideal for beam-sensitive battery materials
CLARA GM Mat. Science
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Tescan UniTOM XL


Engineered for non-destructive 3D imaging, UniTOM XL delivers high-resolution scans of complete lithium-ion cells, components, and modules.

  • Large-format micro-CT: Image cylindrical, pouch, and prismatic batteries without disassembly
  • Sub-micron voxel resolution: Capture fine electrode geometry, tabs, and separators in full 3D
  • Dynamic & in-situ capability: Visualize heating, cooling, electrolyte dynamics, and gas formation in real time
  • Compatible with VGSTUDIO MAX & Panthera™: Advanced segmentation, analysis, and digital twin integration
MICRO_UniTOM_XL_1 (1)-1
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Tescan TIMA


Purpose-built for raw material optimization and recycling, TIMA delivers automated mineralogy at particle scale.

  • Automated EDS-based mineral identification: Map lithium-bearing phases like spodumene, lepidolite, and amblygonite
  • Particle-based analysis: Assess grain size, liberation, and mineral associations for process optimization
  • Integrated workflows: Supports upstream resource modeling and downstream black mass recycling
  • Quantitative deportment analysis: Track lithium, cobalt, and nickel across size fractions
TIMA GM
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Tescan SPECTRAL CT


An advanced spectral detection module for UniTOM XL, enabling material separation and chemical imaging.

  • Spectral CT capability: Differentiate materials based on X-ray absorption spectra
  • Elemental mapping: Visualize distribution of heavy vs. light elements in electrodes and casings
  • Non-destructive: Analyze internal defects and compositional variation in sealed cells
  • High sensitivity: Supports advanced R&D and QA workflows in battery development

Tescan ToF-SIMS Module


Integrated within Tescan FIB-SEM platforms, ToF-SIMS provides high-sensitivity surface and interface chemistry mapping.

  • Lithium and electrolyte mapping: Track elemental and isotopic distributions across electrode interfaces
  • 2D and 3D depth profiling: Reveal chemical gradients through SEI or solid-state interfaces
  • Correlative with SEM/FIB: Align chemical and structural data in one dataset
  • Essential for solid-state research: Study adhesion, ion mobility, and interface degradation

Tescan RSTEM (Rotational STEM)


An integrated STEM mode within AMBER X 2 for nanometer-scale subsurface analysis.

  • Rotational STEM imaging: Enhance contrast and resolution for thin lamella characterization
  • Nanostructural analysis: Visualize SEI layering, intergranular cracking, and cathode degradation
  • Correlative with FIB prep: Prepare lamella and analyze nanoscale details in one workflow
  • Ideal for advanced failure studies: Detect atomic-scale degradation mechanisms in electrodes

Tescan Essence™ Software


A modern SEM workflow automation platform that simplifies complex analyses.

  • Automated particle analysis: Generate size, morphology, and distribution data for powders
  • Intuitive interface: Streamline image acquisition and reporting with minimal training
  • Integrated statistics: Produce reliable datasets for QC and R&D labs
  • Scalable workflows: Move seamlessly from R&D to production environments

Tescan Acquila™ Software + In-Situ Heating Stage


A dynamic CT acquisition platform integrated with UniTOM XL for thermal experiments.

  • In-situ heating integration: Perform controlled heating and cooling of cells during scanning
  • Scriptable acquisition: Automate temperature protocols and time-lapse imaging sequences
  • Real-time visualization: Track electrolyte movement, gas pocket formation, and structural changes
  • Advanced experimental flexibility: Combine mechanical, thermal, and dynamic CT in one setup

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