Quality engineering in battery manufacturing is the discipline of preventing failures before they reach a customer, and of proving that a cell, module, or pack meets its specification consistently, not just on the units that happen to get tested. It sits alongside Cell Manufacturing and Pack Manufacturing rather than inside them, because the same quality methods apply across every stage: electrode coating, cell assembly, module build, and pack integration all use the same underlying toolkit of failure analysis, process control, and inspection.
This category brings together the risk-analysis methods, defect knowledge, and inspection techniques used to design and run a quality programme for battery products, from first-principles design risk through to production process control and end-of-line verification.
Risk analysis
- Failure Mode and Effects Analysis (FMEA) in Battery Design – the core method for systematically identifying failure modes at design, process, and system level, and prioritising engineering effort against them. Covers DFMEA, PFMEA, System FMEA, RPN versus Action Priority scoring, and how FMEA feeds into the ISO 26262 HARA process.
- FMEA Worksheet Template – downloadable spreadsheet with worked examples at cell, pack, and BMS level.
- Worked example: Cell-level DFMEA – separator failure modes and internal short circuit
- Worked example: Pack-level FMEA – busbar joint failure modes and contact resistance
- Worked example: BMS/System FMEA – current sensor drift and SOC estimation error propagation
Defects and root cause
- Cell Defects
- Pack Defects
- Investigation of Catastrophic Battery Failures
- Slitter Burrs, Waviness and Delamination
- Cell Sample Maturity
Inspection and detection
- Using CT Scanning to Detect Battery Defects
- Analysis Workflows for XCT Data
- End of Line Testing