What happens inside a battery cell when it fails? Until now, cell manufacturers and vehicle integrators have had to rely on simulations, destructive testing methods, and indirect measurements. The Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMI, has developed a globally unique high-speed X-ray system that makes dynamic processes inside large-format prismatic cells visible in real time for the first time. Together with the German cell manufacturer PowerCo, a Volkswagen Group company, Fraunhofer EMI is now bringing this technology into industrial use.

The system combines high-performance X-ray technology with a specially designed battery test chamber and advanced sensor systems that simultaneously capture temperature, pressure, voltage, and gas flow. Recording up to 1,000 images per second, it reveals processes such as gas formation, material displacement, and crack propagation inside the cell at extremely high resolution—events that until now have remained hidden from view.

“Our in-situ method allows us to see what happens inside a cell in fractions of a second—in real time and at the highest resolution,” said Dr. Sebastian Schopferer, Head of Battery Safety at Fraunhofer EMI. “This fundamentally changes how we understand battery design and safety.”

A key engineering milestone was the development of a protective chamber that reliably shields sensitive X-ray components from the extreme conditions generated during lithium-ion cell thermal runaway.

Already in Use Within Volkswagen Group

Still image from an X-ray video recorded during a nail penetration test of a prismatic lithium-ion cell.

This technology is more than theory: Fraunhofer EMI has already used it for several German car manufacturers, including VW and Audi, to characterize material ejection during thermal runaway and propagation behavior in multi-cell configurations. The resulting data enables engineers to assess cell designs based on directly observed processes and refine simulation models with greater precision—delivering direct added value for product development and certification processes.

Transfer to Industry by 2028

In the next phase, Fraunhofer EMI and PowerCo will transfer the technology into industrial use. Fraunhofer EMI brings expertise in materials research, battery abuse testing, and high-speed imaging. PowerCo contributes production requirements and access to real-world cell types.

Initial results from the collaboration are already feeding into the development of optimized production cells at PowerCo, accelerating the path from research to industrial implementation. The system is scheduled for installation at PowerCo’s Salzgitter site in 2028.

Designed as a modular platform, the system can be scaled to different cell formats and new cell chemistries—an important advantage for future battery development.

“With in-situ high-speed X-ray imaging, we are taking battery research to a new level,” said HW Vassen, CTO of PowerCo. “For the first time, we can make the dynamic processes inside cells visible in real time and in slow motion. This unprecedented depth of insight allows us to optimize battery cell safety and design in a highly targeted way and bring innovations into industrial use much faster. Together with Fraunhofer EMI, we are advancing high technology made in Europe and are strengthening Europe’s role in the battery industry.”

For more information: www.emi.fraunhofer.de