Lumafield, a provider of industrial X-ray CT technology, has released the results of a large-scale study evaluating the safety and quality of 18650 lithium-ion cells, a format widely used across industries including electronics and some electric vehicles (EVs).
The study scanned more than 1,000 battery cells from ten brands and revealed a sharp divide between high-quality OEM products and low-cost or counterfeit alternatives.
Nearly eight percent of the low-cost or counterfeit batteries tested exhibited a dangerous defect known as negative anode overhang. However, none of the 300 OEM cells from Murata, Samsung, or Panasonic showed this issue.
Industrial CT scans further demonstrated that authentic OEM cells maintain precise alignment and consistent manufacturing quality, underscoring their reliability for demanding applications. The 18650 cells have been widely used in EVs, valued for their cost-effectiveness and scalability when assembled into larger battery packs.
Although many manufacturers have since shifted to newer formats such as 2170 and 4680 cells, a significant number of vehicles on the road continue to rely on 18650 technology. Significantly, the types of defects identified in Lumafield’s scans, such as negative anode overhang and layer misalignment, are not limited to 18650 cells and can present risks in other cylindrical formats as well.
For EV engineers and manufacturers, the findings emphasize the need to secure supply chains and verify cell quality, particularly in systems where dozens of cells are assembled into packs. Advanced CT inspection, once too slow and expensive for production, is now accessible through Lumafield’s high-speed, automated CT solutions, which can scan more than 12 parts per minute and flag defects in real time.
“Customers depend on lithium-ion batteries for safety-critical applications ranging from medical devices to EVs,” said Eduardo Torrealba, co-founder and CEO of Lumafield. “Our research highlights both the risks of counterfeit cells and the proven quality of leading OEMs. Rapid CT inspection gives manufacturers the tools to enforce safety and ensure only reliable components reach the market.”
The Lumafield Battery Quality Report provides full study details and is available as a free download here.
Filed Under: Batteries, Technology News