Transforming Battery Quality Control with Direct Electrolyte Leak Detection

The rapid rise of rechargeable batteries in electric vehicles, renewable energy storage, and portable electronics has driven the demand for advanced manufacturing technologies. Among these technologies, precise and reliable leak testing plays a pivotal role in ensuring product safety, quality, and performance.

Our electrolyte leak testers (ELT) are designed to meet the stringent demands of modern battery production, from large-scale factories to R&D labs. Unlike conventional methods such as helium leak testing, electrolyte leak testing offers direct identification of leaks by detecting liquid electrolyte outside of sealed battery cells. This method remains the only effective solution for end-of-line leak testing of fully assembled metal-ion battery cells.

Lithium-ion batteries contain a liquid electrolyte essential for their operation. We are also detecting leaks that will not allow for electrolyte to escape but for humidity to penetrate. Our ELT solutions are designed to detect even the smallest leaks, reducing warranty costs, ensuring safety, and promoting sustainability by preventing defective cells from reaching the market.

By identifying defects early in the production process, manufacturers can reduce waste, improve yields, and lower overall production costs. Moreover, precise leak detection contributes to a more sustainable use of critical resources, helping to reduce the environmental impact of battery production.

The battery industry is characterized by rapid changes in technologies, form factors, and materials. Staying ahead of these trends requires a flexible and innovative approach. Since the launch of the ELT3000 in 2019—the first commercial solution for direct electrolyte leak testing—we have continuously evolved our product line to meet industry needs.

With the introduction of the ELT3000 PLUS and, more recently, the ELT Vmax, we have significantly enhanced scalability, cycle time, and contamination prevention. The ELT Vmax, in particular, is tailored for high-speed, fully automated production lines, capable of testing thousands of cells per hour with cycle times well below 15 seconds.