Production and Quality Assurance in Battery Manufacturing

Quality, reproducibility, and cost-efficiency are central to scaling lithium-ion battery production. From electrode porosity to separator integrity, even subtle variations can impact safety, performance, and long-term reliability.

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Tescan solutions for Batteries

PRODUCTION AND QUALITY ASSURANCE ACROSS THE CELL LIFECYCLE

Evaluation of Lithium-Ion Battery Electrode Porosity

Understanding electrode porosity is key to predicting electrolyte uptake and cycle stability. Large-volume FIB-SEM tomography with Tescan AMBER X 2 delivers statistically meaningful 3D datasets that go beyond conventional 2D cross sections.

Analyze void fraction and pore networks in 3D
Quantify structural variation across large electrode volumes
Correlate porosity with performance, lifespan, and manufacturing quality

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Characterization of Particle Size in Battery Powder

Particle size and morphology in active material powders influence electrode packing, coating uniformity, and long-term stability. With UHR SEM and automation, Tescan CLARA enables fast, reproducible particle size analysis across batches.

Quantify particle size, shape, and texture in Ni-based powders
Use automated workflows for consistent quality control
Optimize powder selection to balance capacity and stability

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High-Resolution Analysis of Battery Separators

Separators are critical for both ion transport and safety. Tescan CLARA UHR SEM reveals nanometer-scale pore and fiber structures without conductive coating, preserving the true surface morphology and helping manufacturers control separator quality.

Visualize pores and fiber networks at nanometer resolution
Assess morphology to ensure mechanical and thermal stability
Provide quality metrics for consistent production outcomes

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Insights into the Role of Porosity in Lithium-Ion Battery Electrodes

Porosity is a hidden variable that controls electrolyte flow, charge transport, and cycling behavior. Using Tescan UniTOM HR, researchers can non-destructively map pore distribution and connectivity in electrodes.

Capture full-cell architecture with multi-scale micro-CT
Measure pore size and connectivity at sub-micron resolution
Link porosity to electrolyte infiltration and ionic conductivity

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Investigating Battery Anode Overhang Using X-ray Micro-CT

Anode overhang must remain within strict tolerances to avoid lithium plating and safety risks. Tescan UniTOM XL micro-CT quantifies overhang geometry across assembled cylindrical cells.

Visualize jelly roll geometry in full 3D
Detect misalignment and asymmetry in electrode placement
Map overhang variation to support design and quality assurance

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Non-Destructive Evaluation of 26650 Lithium-Ion Batteries

Internal features such as tab alignment, cap structure, and electrode symmetry are vital for safe, durable cylindrical cells. Tescan UniTOM XL reveals them without cutting open the battery.

Inspect electrode tabs, caps, and current interrupt devices in 3D
Detect overhang deviations that cause plating or gas evolution
Segment components for digital twin integration and quality assurance

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Tescan Solutions

FOR BATTERY QUALITY ASSURANCE

Tescan AMBER X 2 Plasma FIB-SEM

High-throughput FIB-SEM for large-volume electrode analysis and failure control.

Acquire 3D datasets of electrode porosity, microstructure, and composition
Perform automated, statistically meaningful tomography
Support process optimization with reproducible results

Tescan CLARA UHR SEM

Ultra-high-resolution SEM for sensitive battery materials and powders.

Visualize particle morphology and size distribution
Analyze separator pores and fiber networks at the nanometer scale
Use automated workflows for consistent quality assurance

Tescan UniTOM HR

High-resolution micro-CT for non-destructive electrode and material imaging.

Quantify and map electrode porosity and pore connectivity in 3D
Capture microstructural variation across full cells
Link morphology to ionic transport and battery performance

Tescan UniTOM XL

Large-scale micro-CT for assembled battery inspection and geometry control.

Scan full cylindrical cells without disassembly
Quantify anode overhang and internal alignment
Detect defects and asymmetries impacting safety and lifespan

Explore the system that moves your research forward

Tescan instruments are designed to help you get answers. Fast and precisely. Talk to our experts and see the solution in action.

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GET IN Touch

Where can you find us:

Tescan
Libušina třída 21
623 00 Brno
Czech Republic

info@Tescan.com