Battery manufacturing — from cell to module and pack — involves highly sensitive processes, multi-material assemblies and stringent safety, quality and reliability requirements. Small geometric deviations, internal defects or assembly failures can result in performance losses, safety risks, production rejections or field failures.
NM3D Ibérica positions itself as a specialized technical service provider for the battery industry, supporting manufacturers and integrators with non-destructive testing, dimensional metrology, 3D scanning, reverse engineering and additive manufacturing, focused on solving concrete development, industrialization and production challenges.
Context and challenge
In industrial practice, battery manufacturers face recurring problems such as:
- internal defects not visible externally
- geometric variations affecting assembly and sealing
- failures in welds, connections and interfaces
- internal misalignments in cells and modules
- difficulties identifying root cause of failures
- need to validate process changes quickly
These problems cannot be solved with visual inspections or surface measurements alone. They require advanced technical testing.
The solution or technology
X-Ray and Industrial Computed Tomography Testing
Addressing internal problems in cells, modules and packs
Industrial Computed Tomography is one of the most critical tests in the battery sector, as it allows analysis of system interiors without disassembly or destruction.
What problems it solves:
- identification of internal defects in cells
- analysis of layer and component misalignment
- detection of voids, inclusions and discontinuities
- validation of welds and internal connections
- verification of structural integrity of modules and packs
What decisions it enables:
- accept or reject batches
- adjust process parameters
- validate design changes
- identify causes of production or test failures
NM3D Service: CT testing with clear technical reports, 3D evidence and root cause analysis support.
Dimensional metrology applied to battery components and systems
Ensuring correct assembly and production repeatability
Dimensional metrology is essential to ensure that housings, modules, supports and interfaces meet required functional tolerances.
What problems it solves:
- assembly difficulties between components
- sealing and fitting failures
- deformations after production processes
- dimensional variations between batches
Tests and services performed:
- complete dimensional inspection of housings and modules
- First article and pre-series validation
- dimensional control in production
- laboratory or on-site measurements
What decisions it enables:
- validate dimensional conformity
- stabilize production processes
- reduce rework and rejections
- ensure series repeatability
3D Scanning and Reverse Engineering as industrial diagnostic tools
When CAD no longer matches reality
In many battery projects, the problem is not just measuring, but understanding how the real part deviates from the theoretical model.
What problems it solves:
- absence or outdated CAD models
- unforeseen geometric deviations
- need to adapt existing components
- analysis of deformations in plastic or structural parts
Services provided:
- 3D scanning of components and assemblies
- CAD vs. real part comparison
- reverse engineering for corrections and re-engineering
- digital documentation for production and maintenance
These tests enable faster technical decisions and reduce unproductive iterations.
Additive manufacturing as direct support for industrialization and testing
Solving problems quickly, without stopping production
In the battery sector, additive manufacturing is a practical tool to respond quickly to industrial needs.
Typical applications:
- functional prototypes for validation
- assembly fixtures and jigs
- supports for testing and inspection
- auxiliary parts for production line
- large-format components for validation
What problems it solves:
- development delays
- dependence on final tooling
- difficulties testing new solutions
- need for rapid production adjustments
Large-format production capability enables rapid response to real factory problems.
Industrial applications
NM3D supports the battery sector at all stages:
Development
- Computed tomography testing for internal validation
- Functional prototyping
- reverse engineering
Industrialization
- dimensional validation
- non-destructive testing
- process optimization
Production
- quality control
- internal inspection by sampling
- deviation and failure analysis
Failure analysis and continuous improvement
- root cause identification
- component re-engineering
- process optimization
Results and benefits
By combining non-destructive testing, dimensional metrology, 3D scanning, reverse engineering and additive manufacturing, NM3D Ibérica helps the battery industry to:
- increase system safety
- reduce rejections and rework
- accelerate technical decisions
- improve final product reliability
- respond quickly to production problems
How NM3D can help
NM3D Ibérica offers specialized technical services for the battery industry, including industrial Computed Tomography testing, dimensional metrology, 3D scanning, reverse engineering and additive manufacturing. We support manufacturers and integrators at all stages of the industrial cycle — development, industrialization, production and failure analysis — with clear technical reports and decision-making support.
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NM3D positions itself as an industrial technical service provider, prepared to respond to real problems in battery manufacturing.