Join us as we explore key reasons why battery teardowns and FMEA are essential for battery programs.
Battery failures are rarely random. They’re usually rooted in design choices, material interfaces, or subtle manufacturing issues that aren’t visible to the naked eye. Without opening the battery and analyzing it systematically, inherent risks can stay hidden until they show up as safety incidents, field failures, or costly recalls.
At Acculon Labs, our Battery Teardown & FMEA services are designed to expose those risks so that they can be mitigated and managed.
By physically deconstructing battery cells, modules, and packs–and pairing that insight with a rigorous Failure Mode and Effects Analysis (FMEA)–we help organizations answer critical questions:
- Where can this battery fail?
- Why would it fail?
- How severe would the impact be—and how likely is it to happen?
Why this matters:
- Prevent safety events by identifying failure mechanisms before they escalate
- Improve reliability by uncovering weak points in materials, assembly, or design
- Reduce warranty and recall risk through early detection of manufacturing defects
- Make better design and sourcing decisions using physical evidence, not assumptions
- Accelerate root cause investigations when performance or degradation issues arise
Our teardown-driven solutions combine controlled disassembly, high-resolution imaging, materials characterization, cross-sectional analysis, and expert-led FMEA to connect what we see physically with how and why failures occur.
The result? Clear, prioritized risk insights and actionable recommendations that strengthen battery performance, safety, and long-term reliability. Interested in learning more? Let’s have a conversation!