Electric mobility has brought new challenges to the automotive industry. Today’s vehicles integrate high-density batteries, high-voltage wiring, complex connectors, thermal systems, critical welds, electronic modules and multi-material assemblies where a small internal defect can compromise performance, safety or reliability.
At NM3D Ibérica, we help industrial companies analyse these components through industrial X-ray computed tomography, a non-destructive inspection technology that makes it possible to observe the inside of parts without cutting, disassembling or damaging the product.
Industrial CT transforms a physical component into a 3D digital volume. From this volume, it is possible to visualise internal sections, measure hidden geometries, identify defects, compare the part with the CAD model, analyse assemblies and technically document the real condition of the component.
Why CT Is So Relevant in Electric Mobility
Electric vehicle components are increasingly compact, integrated and demanding. Many critical areas are hidden inside housings, encapsulations, modules, connectors, internal channels or interfaces between materials.
A visual inspection only shows the exterior. A destructive test requires cutting the part and may alter precisely the area that needs to be studied. Industrial CT solves this problem: it makes it possible to see inside the component in its original condition.
This is especially important in the following stages:
Product Development and Validation
To understand whether the design has been correctly executed, validate prototypes and compare different construction solutions.
Industrialisation
To verify whether the manufacturing process is producing consistent parts, with correct internal geometries and compliant assemblies.
Quality Control
To detect internal defects, validate suppliers, analyse production samples and document results.
Failure Analysis
To investigate breakdowns, field defects, assembly problems or anomalies without destroying the original evidence.
Reverse Engineering and Internal Metrology
To reconstruct internal geometries, measure thicknesses, verify channels, cavities, fittings, welds and interfaces that are not accessible by conventional methods.
What NM3D Ibérica Is Analysing Using CT
At NM3D Ibérica, we are applying industrial CT to the analysis of different components associated with electric vehicles, hybrid vehicles and advanced mobility systems.
The main areas of application include:
1. Battery Components for Electric Vehicles
Batteries are one of the most critical assemblies in an electric vehicle. Their safety depends on the quality of the cells, modules, electrical connections, insulation, encapsulation, thermal systems and final assembly.
CT makes it possible to analyse battery components without disassembly, observing internal structures and critical areas that would not be visible externally.
We can support the analysis of:
• cylindrical, prismatic or pouch cells;
• battery modules;
• battery subassemblies and housings;
• separators, internal areas and alignments;
• encapsulations and resins;
• internal insulation;
• deformations, voids, inclusions or misalignments;
• contact areas between components;
• the condition of the component before and after mechanical, thermal or functional tests.
This information is useful for engineering, quality and production teams that need to understand whether the part is compliant, whether there is an internal risk, or whether the manufacturing process is stable.
2. Electrical Cables, Connectors and Crimps
In an electric vehicle, wiring is not merely an auxiliary element. Power cables, connectors, terminals and crimps are essential to ensure stable electrical conduction, low resistance, thermal safety and reliability in service.
CT makes it possible to visualise the inside of terminals and electrical connections in order to assess how the wires are positioned, compressed and distributed inside the crimp.
Examples of analysis:
• positioning of conductors inside the terminal;
• crimp compression;
• broken or deformed wires;
• voids between conductor and terminal;
• insufficient contact;
• excessive or insufficient compression;
• internal defects not visible from the outside;
• analysis of encapsulated or overmoulded connectors;
• validation of high-voltage wiring.
This analysis is especially relevant when the connection appears correct from the outside but may have internal problems that increase electrical resistance, heating or the risk of intermittent failure.
3. Welds, Brazing and Electrical Connections
Welds in battery components and electrical systems are critical areas. In applications such as tab-to-busbar connections, busbars, terminals, contacts, metal joints and electrified subassemblies, joint quality directly influences electrical resistance, mechanical strength, thermal dissipation and system safety.
Industrial CT makes it possible to observe these connections internally and identify defects such as:
• porosity;
• lack of fusion;
• cracks;
• inclusions;
• voids;
• joint discontinuity;
• insufficient penetration;
• excess material;
• localised deformation;
• misalignment between joined components.
This capability helps validate welding parameters, compare processes, analyse production parts and investigate causes of failure.
4. Heating and Cooling Systems
Electric vehicles depend on efficient thermal systems. Batteries, power electronics, inverters, electric motors and charging systems need to maintain controlled temperatures to ensure performance and durability.
Many of these components include internal channels, cooling plates, heat exchangers, fluid circuits, bonded areas, gaskets and thermal interfaces that cannot be assessed from the outside alone.
With CT, it is possible to analyse:
• internal cooling channels;
• cold plates and thermal management components;
• internal obstructions;
• channel deformations;
• wall thicknesses;
• missing material;
• porous areas;
• voids in thermal interface materials;
• gaskets, seals and interfaces;
• misalignments in assembled components;
• potential critical areas for leakage or loss of thermal efficiency.
CT does not replace all functional tests, such as leak tests or thermal tests, but it adds a fundamental internal view: it shows where the real geometry is, how the channels are formed and whether hidden structural defects exist.
5. Plastic, Metallic and Multi-Material Parts
Many electric vehicle components combine technical plastics, metals, elastomers, resins, adhesives, inserts and electronic components. This combination of materials creates inspection challenges, because internal interfaces can hide defects or assembly failures.
NM3D Ibérica can apply CT to analyse:
• injection-moulded parts with metal inserts;
• overmoulded components;
• technical housings;
• covers, supports and casings;
• parts with internal cavities;
• components with seals or gaskets;
• multi-material parts;
• defects in plastics, such as pores, sink marks, cracks or incomplete filling;
• the position of inserts, screws, clips or internal elements;
• correct assembly of subassemblies.
This analysis is useful for manufacturers, suppliers and quality teams that need to validate the inside of complex parts without resorting to cutting.
6. Electronics, Sensors and Encapsulated Components
Power electronics and control systems in electric vehicles include circuit boards, welds, connectors, sensors, encapsulations and protective materials. In many cases, the failure may be hidden inside a resin, housing or internal connection.
CT makes it possible to observe:
• solder joints on electronic boards;
• voids in encapsulation;
• component position;
• internal cracks;
• connector defects;
• interface failures;
• foreign bodies;
• bubbles or delaminations;
• integrity of electronic subassemblies.
This information supports failure analysis, supplier validation and the improvement of assembly processes.
7. CAD Comparison, Metrology and Technical Reports
Industrial CT is not only used to “see images”. The data collected can be used for measurements and quantitative analyses.
From the 3D volume, we can perform:
• comparison between the real part and CAD;
• internal and external dimensional analysis;
• colour deviation maps;
• thickness measurement;
• porosity analysis;
• measurement of internal volumes;
• section extraction;
• assessment of circularity, flatness, alignment or positioning;
• defect documentation;
• technical reports for engineering, quality or the end customer.
This makes it possible to transform a visual inspection into a technical analysis supported by measurable data.
The Value for Engineering, Quality and Production
Industrial CT makes it possible to answer questions that often cannot be answered using conventional methods:
• Is the part correctly assembled on the inside?
• Does the weld have porosity or lack of fusion?
• Is the cable correctly crimped?
• Is the cooling channel clear and does it have the correct geometry?
• Is there missing material?
• Did the component deform after testing?
• Did the failure originate in manufacturing, assembly or service?
• Is the part compliant with the CAD model?
• Is the defect localised or recurring?
• Is the supplier delivering consistent parts?
• Can we validate the component without destroying it?
By answering these questions, CT helps reduce uncertainty, accelerate decisions, avoid unnecessary disassembly and improve product reliability.
NM3D Ibérica: Seeing the Invisible to Improve Industrial Quality
At NM3D Ibérica, we apply advanced metrology, scanning and industrial CT technologies to support companies that develop, produce or validate critical components.
In the electric mobility sector, we are focused on the analysis of batteries, electrical cables, connectors, welds, heating and cooling systems, electronic components, multi-material parts and all elements whose internal quality is essential to vehicle safety and performance.
Our approach transforms physical components into technical data, helping engineering, quality, production and maintenance teams make faster, safer and better-informed decisions.
With industrial CT, we no longer depend only on what can be seen from the outside. We can understand what is happening on the inside.
If you want to evaluate battery components, wiring, welds, thermal systems or other critical parts using CT, speak to NM3D Ibérica.