Scaling up Production of Ultrasound-based Battery Inspection System

Project Update

In 2023, the project focused on advancing the EchoStat system from early prototypes toward a commercially viable inspection platform. The team refined core ultrasound sensing and signal processing capabilities to improve defect detection accuracy and repeatability, while demonstrating the ability to identify key manufacturing defects in lithium-ion battery cells. Initial system architectures were developed and tested in lab environments, and early engagement with battery manufacturers helped define system requirements, throughput targets, and integration constraints. The team also began identifying critical components and supply chain needs, laying the groundwork for future manufacturing scale-up. These efforts established a strong technical foundation and validated the feasibility of non-destructive, in-line ultrasound inspection for battery production.

In 2024, the project progressed from prototype validation to system integration and manufacturing development. The team designed and assembled more advanced, factory-relevant EchoStat systems (e.g., ARRAY, RASTER, and THETA configurations) and validated their performance in detecting defects under more realistic production conditions. Significant work was completed to define manufacturing workflows, quality control protocols, and system-level documentation, alongside development of a unit cost model to guide commercialization. The team also initiated pilot manufacturing activities and began building out relationships with key suppliers for ultrasound transducers and electronics. In parallel, Liminal engaged with multiple global battery manufacturers to prepare for system deployments and gather feedback on system performance and integration requirements.

In 2025, the project focused on scaling manufacturing readiness and advancing toward low-rate initial production (LRIP). The team established a more robust and reliable supply chain for critical components and successfully built and validated a pilot manufacturing line for EchoStat systems. Manufacturing documentation, quality control processes, and production metrics were further refined to support consistent and repeatable system builds. The company worked closely with Tier 1 battery manufacturers and automation partners to secure system orders and support early deployments, demonstrating the technology’s value in commercial production environments. These efforts positioned the project to transition into low-volume production and facility expansion in 2026 to meet growing customer demand.