High-Speed X-Ray Battery Imaging Enables Real-Time Cell Analysis

Fraunhofer EMI has developed a high-speed X-ray battery imaging system that can show what happens inside large battery cells in real time. Announced on August 13, the technology combines high-powered X-rays with a specially designed battery test chamber and multiple sensors to observe internal battery behaviour under demanding operating conditions. The system can capture up to 1,000 images per second, allowing engineers to see gas formation, material movement and cracks developing inside lithium-ion battery cells. Together with PowerCo, Fraunhofer EMI is now preparing the technology for industrial application and further battery development.

High-Speed X-Ray System Captures Battery Behaviour

The imaging system combines high-powered X-rays with sensors that continuously measure temperature, pressure, voltage and gas flow during battery testing. This combination provides engineers with both visual information and measurable operating data, helping them understand how internal cell conditions change over time. The ability to capture as many as 1,000 images per second makes it possible to observe rapid physical processes that conventional inspection methods may not capture effectively. Internal gas formation, material movement and cracking can therefore be studied as they occur, providing detailed information for battery development, failure analysis and safety testing.

Protective Chamber Enables Thermal Runaway Testing

A specially designed protective chamber allows the X-ray system to operate safely while a lithium-ion battery undergoes thermal runaway. Thermal runaway can expose test equipment to extreme conditions, making direct observation of the event technically challenging. The protective design shields sensitive X-ray equipment while allowing the internal behaviour of the battery cell to be recorded. This capability gives researchers a way to study the progression of battery failures and the physical processes occurring inside cells during severe events. The resulting observations can support more detailed validation of cell designs, simulations and safety-related testing procedures.

Fraunhofer EMI and PowerCo Combine Expertise

Fraunhofer EMI contributes its expertise in battery testing and high-speed imaging, while PowerCo provides production requirements and real-world battery cells for industrial development. The collaboration is intended to connect advanced laboratory measurement capabilities with practical requirements from battery manufacturing. Fraunhofer EMI has already applied the technology with manufacturers including Volkswagen and Audi to investigate battery failures and thermal runaway. The resulting data helps engineers understand failure mechanisms and use those findings to improve cell designs, simulations and safety testing.

Technology Supports Future Battery Development

The results generated through high-speed imaging are already supporting the development of improved battery cells at PowerCo. By making internal battery processes visible during demanding test conditions, the system can provide information that complements conventional electrical and thermal measurements. Its modular architecture also allows the system to be adapted to different battery sizes and chemistries, increasing its potential usefulness as battery technologies evolve. This flexibility is particularly relevant for future cell development, where different designs and chemistries may require tailored testing approaches and detailed analysis of internal behaviour.

Industrial Installation Planned at Salzgitter

PowerCo plans to install the modular system at its Salzgitter site in Germany in 2028. The planned installation represents a move from advanced research and manufacturer testing toward an industrial battery-development environment. At the site, the technology is expected to support testing of production-relevant battery cells while providing high-speed visual data on internal processes. The combination of real-world cells, production requirements and detailed X-ray observation could help engineers identify potential weaknesses earlier and improve battery development processes. Its ability to accommodate different battery sizes and chemistries also provides scope for continued use as future cell technologies develop.

Frequently Asked Questions

What is the high-speed X-ray battery imaging system developed by Fraunhofer EMI?
The high-speed X-ray battery imaging system uses high-powered X-rays, a protective test chamber and sensors to observe internal battery behaviour in real time. It can capture up to 1,000 images per second, revealing gas formation, material movement and cracks inside lithium-ion cells. The system can also operate during thermal runaway while protecting sensitive X-ray equipment from extreme conditions. Fraunhofer EMI and PowerCo are preparing the technology for industrial use, with installation planned at PowerCo's Salzgitter site in Germany in 2028.