Industrial solution

Secondary Battery

Electrode, assembly and formation — from foil intake to finished cell.

Battery manufacturing spans electrode, assembly and formation, with defect modes that vary at every stage and bear directly on safety. DSTEK combines 2D+2.5D+3D imaging, purpose-built optics and deep-learning AI to inspect and measure prismatic, pouch and cylindrical cells alike.

40+Pouch defect types
0.025mm3D point pitch
3Cell formats supported

Scope

What we inspect

Electrode

Foil intake, coating, roll press, notching — pinholes, creases, oxidation staining, dressing protrusion
Assembly

Winding, stacking, ultrasonic welding, top-cap welding, can insertion — blow-through, missing welds, step height
Formation

Filling, helium leak, ageing, X-ray, sealing-pin welding — leakage, pinholes, broken welds
Prismatic

Blue-film bubbles, creases, tears and lifting; terminal scratches, contamination and weld slag; safety-vent damage and leakage — 30+ types
Pouch

Surface scratches, bubbles, indentation, creases and tears; seal cracks and leakage; tab defects; laminate film damage — 40+ types
Cylindrical (18650 / 4680)

Pits, deformation, impact marks and contamination; blue-film defects; tab hole blockage, folding and weld faults — 30+ types

Applications

Representative inspection tasks

A selection of what we have actually run on the line — not the full list. New inspection targets are approached the same way.

Foil raw-material intake

Aluminium foil pinholes, holes, burn marks, scratches and protrusions; copper foil press marks, black spots, creases and oxidation staining
Coating inspection

Voids, print indentation, pinholes, tears, creases, dressing protrusion
Bare cell surface

Separator scratches, protrusions, creases and tears; film damage; oil staining; separator contamination
Cathode and anode tab welding

Tears, scratches and creases; blow-through, missing welds, protrusions, pinholes, over-welding
Flexible connector laser welding

Weld-mark tape presence, length and position; blow-through points; broken welds; misalignment; seam width
Mylar film wrapping

Edge distance on all four faces, weld-mark area, heat-fusion defects, adhesive presence and creasing
Aluminium case inspection

Flatness, denting, scratches, contamination, electrolyte leakage, swelling, terminal contamination and weld debris
Cover plate full weld

Blow-through, pinholes, missing welds, broken welds, step height
Sealing pin welding

Fill-port location capture and laser guidance; pinhole blow-through; broken welds (≥1mm rejected)
Blue film inspection

Bubbles, white spots, protrusions, creases, tears, scratches, overlap width, height, foreign matter, lifting, handling marks
Half-module 3D measurement

3D line laser with 1μm/pulse encoder, 0.025mm point pitch, flatness measurement

Prismatic lithium-ion cell manufacturer
QR code verification

Code scratches and damage, seal weld appearance, safety-vent damage, contamination and leakage