CT scans show fire risk with cheap batteries

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An X-ray analysis of over 1000 lithium-ion batteries reveals significant differences in quality between branded products and cheaper alternatives. The company Lumafield used computer tomography scanners to X-ray 18650 cells from various manufacturers and, according to The Verge, found dangerous production defects in cheap batteries that increase the risk of fires and explosions.

The researchers tested batteries from ten different suppliers: three original manufacturers such as Samsung and Panasonic from specialized retailers, three suppliers of rewrap batteries, and four companies that sell cheap or counterfeit products via large online marketplaces such as Temu. They focused on 18650 cells, which are used in electric toothbrushes, tools, e-bikes, power banks, and even electric cars.

Critical defects only with low-cost suppliers

Of the 1054 batteries scanned, 33 exhibited a serious production defect known as negative anode protrusion. According to Lumafield, this defect significantly increases the risk of internal short circuits and battery fires and also shortens the service life of the cells. All 33 defective batteries came from the group of 424 cheap and counterfeit products tested. In contrast, the researchers found no such shortcomings in branded products from Samsung, Panasonic, and other established manufacturers.

Some cheap suppliers advertised unrealistic capacities of 9900 mAh, while real 18650 cells typically reach 3000 to 3450 mAh. Practical tests indicated that the advertised values were not only exaggerated; the actual capacity was less than 1300 mAh.

Defect rate increases dramatically with counterfeits

The probability of the dangerous anode protrusion defect in cheap and counterfeit batteries is just under eight percent. For two brands with particularly unrealistic specifications, the defect rate even reached 12 to 15 per cent. Rewrap batteries, in which OEM cells are provided with new wrapping, also showed deviations in the anode protrusion, but these were seven times lower than in the cheap products.

In addition to the anode protrusion, the researchers identified further quality defects: all the batteries from the low-cost suppliers had significantly poorer edge alignment of their internal winding layers than the products from established manufacturers. These inaccuracies further increase the risk of short circuits and power losses.

Risk factors increase the potential danger

The defects discovered do not automatically mean that an affected battery will explode or catch fire. However, they significantly increase the probability of such incidents, especially in combination with other stresses such as high temperatures in the car or mechanical damage caused by falls. The study emphasises that batteries from established manufacturers such as Samsung, Panasonic and Murata are safer and more reliable.

Lumafield recommends that consumers opt for reputable brands when buying battery-powered devices. The supposed price advantage of cheaper alternatives could turned out to be an expensive mistake in the long term – not only financially, but also in terms of safety.

(vbr)