On August 13, 2026, Fraunhofer EMI said it had developed a high-speed X-ray system that makes dynamic processes inside large-format prismatic battery cells visible in real time. The institute said the technology can help accelerate the development of safer next-generation cells for the European automotive industry and is now being transferred into industrial use with PowerCo, a Volkswagen Group company.
The system combines high-performance X-ray imaging with a specially designed battery test chamber and sensor systems that measure temperature, pressure, voltage, and gas flow at the same time. According to Fraunhofer EMI, the setup can record up to 1,000 images per second, allowing researchers to observe events such as gas formation, material displacement, and crack propagation inside a cell during operation or failure.
Fraunhofer EMI said the approach provides in-situ data that had previously been difficult to obtain, since manufacturers and vehicle integrators typically relied on simulations, destructive testing, and indirect measurements to assess battery safety. Dr. Sebastian Schopferer, head of battery safety at Fraunhofer EMI, said the method enables the institute to see what happens inside a cell in fractions of a second and at very high resolution.
A key development phase involved designing a protective chamber that shields sensitive X-ray equipment from the extreme conditions created during lithium-ion cell thermal runaway. Fraunhofer EMI said the system has already been used with several German automakers, including VW and Audi, to study material ejection during thermal runaway and propagation behavior in multi-cell configurations. The resulting data can support design assessments and improve simulation models.
Fraunhofer EMI and PowerCo plan to continue the collaboration to bring the technology into industrial applications. PowerCo said the work is already contributing to the development of optimized production cells. The system is scheduled for installation at PowerCo’s Salzgitter site in 2028. Fraunhofer EMI said the modular platform can be adapted to different cell formats and new chemistries, supporting future battery development.
Source: Fraunhofer EMI
