I-Corps: Translation Potential of a Battery Monitoring and Degradation Detection Tool Using Non-Contact Methods

Award ID: 2628075

This I-Corps project is based on the development of a non-contact, laser-based diagnostic technology for assessing the health and integrity of lithium-ion battery cells and packs used in electric vehicles and other energy storage applications. Battery failures in electric vehicles and portable electronics cause thousands of safety incidents annually, drive billions of dollars in recalls, and undermine public confidence in electrified products. However, existing inspection methods are slow, invasive, and unable to detect hidden internal damage before it becomes a hazard. This technology measures microscale surface vibrations and wave responses to identify structural changes inside a battery without disassembly or contact probes, reducing inspection time by up to 70% compared to conventional approaches. It addresses a broad and growing market spanning battery manufacturers, independent test laboratories, fleet operators, maintenance service providers, and second-life or recycling processors. This may improve the safety of electric vehicles on public roads, reduce the burden of premature battery disposal, and lower the economic cost of large-scale recalls. In addition, this technology has the potential to become a standard quality and safety-screening tool across the energy storage industry by enabling earlier detection of defects at lower cost and higher throughput. This I-Corps project utilizes experiential learning coupled with first-hand investigation of the industry ecosystem to assess the translation potential of scanning laser Doppler vibrometry for battery state-of-health and mechanical integrity assessment. The technology combines low-frequency vibration analysis to track global resonance and stiffness changes associated with degradation, and high-frequency guided wave interrogation to detect localized defects such as delamination, swelling, weld defects, or other structural changes. Technical results show that spatially resolved, non-contact vibration measurements can provide mechanical observables that complement electrical and electrochemical indicators. Unlike conventional methods that rely mainly on capacity, voltage, or impedance measurements, this approach adds a structural diagnostic layer that can flag damaged cells or packs earlier and without physical contact. Adoption of this technology may offer users measurable reductions in inspection cycle time, improved confidence in safety and reliability assessments, and a non-invasive diagnostic modality compatible with existing battery testing infrastructure. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

NSF Program Director: Ruth Shuman