In-Line Quality Control of Lithium-Ion Battery Electrodes through Terahertz Scanning
Lookin, Inc.
Recipient
Los Angeles, CA
Recipient Location
30th
Senate District
54th
Assembly District
$529,695
Amount Spent
Active
Project Status
Project Update
This project was completed in 2025. The project developed a compact, high-sensitivity terahertz scanner specifically designed for in-line roll-to-roll electrode inspection. The tool demonstrated real-time, non-destructive detection of common electrode defects such as agglomerates, pinholes, divots, microcracks, and nonuniform coatings with micrometer-level accuracy. It also measures thickness and monitors drying processes, helping manufacturers maintain consistent quality. More than 100 samples from research and commercial sources were evaluated, confirming strong links between detected defects and battery performance. Pilot-scale testing at Navitas Systems demonstrated that the technology works under real manufacturing conditions. It detected flaws invisible to traditional optical inspection and provided near real-time analysis through a user-friendly interface.
These achievements confirm that the terahertz scanner developed provides an effective and practical platform for early-stage quality control. The system combines defect detection, thickness measurement, porosity estimation, and drying process monitoring in a single non-destructive tool. Successful deployment in both laboratory and pilot-scale production environments demonstrates the feasibility of terahertz imaging as a high-yield quality assurance solution for electrode manufacturing lines.
The Issue
Defects introduced during roll-to-roll lithium-ion battery (LIB) electrode manufacturing have a significant impact on electrochemical performance. These imperfections can degrade cycle efficiency, reduce discharge capacity, shorten battery lifespan, and, in severe cases, lead to internal short circuits that pose safety hazards, including the risk of thermal runaway and explosion. Consequently, implementing robust in-line quality control systems for early defect detection is essential to ensure consistent performance and safe, reliable LIB production.
Project Innovation
Lookin, Inc. proposes an innovative solution to address a critical gap in LIB manufacturing: the development of a high-throughput terahertz scanning system for in-line electrode quality control. This technology is designed to enhance manufacturing efficiency and enable the production of high-performance batteries with improved shelf life, greater safety, reduced costs, and shorter lead times. Terahertz waves provide unique capabilities for non-destructive inspection of battery electrodes, making them ideally suited for detecting structural and material defects. The objective of this project is to design and implement a high-sensitivity, high-speed terahertz scanner capable of automatically identifying defective LIB electrodes during production. By reducing scrap rates and improving battery reliability, this innovation supports California’s clean transportation and energy storage goals. Better quality control means safer, longer-lasting batteries at lower cost, which is critical for meeting state mandates on zero-emission vehicles and renewable energy integration.
Project Goals
Project Benefits
This Agreement resulted in the benefits of developing and validating a terahertz-based imaging system for real-time, non-destructive quality control of lithium-ion battery electrodes during roll-to-roll manufacturing. By detecting coating defects, measuring thickness with micrometer accuracy, and monitoring drying behavior, the technology reduces scrap rates, improves battery reliability, and lowers production costs. Successful field demonstrations confirmed its ability to operate at industrial speeds and identify flaws invisible to conventional inspection methods. These advancements support California’s clean energy goals by enabling safer, longer lasting, and more affordable batteries for electric vehicles and energy storage systems. The project also strengthens the state’s innovation ecosystem through the commercialization of university research and fosters economic development in advanced manufacturing.
Affordability
Implementation of this technology will lower costs and enhance the reliability of electric vehicles by improving in-line quality control. Early defect detection minimizes cell rejection rates after fabrication and testing, resulting in substantial cost savings for battery manufacturers and greater confidence in end-user applications.
Safety
Identifying and mitigating battery defects during the manufacturing process will reduce the likelihood of faulty batteries reaching end-users which can support increased safety of battery systems.
Key Project Members
Dr. Nezih Tolga Yardimci
Prof. Mona Jarrahi
Prof. Iryna Zenyuk
Subrecipients
The Regents of the University of California on behalf of the Los Angeles Campus
University of California, Irvine
Match Partners
The Regents of the University of California on behalf of the Los Angeles Campus
University of California, Irvine
Lookin, Inc.
