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The Lumafield Battery Quality Report

Every year, billions of 18650 lithium-ion battery cells are produced, powering everything from our toothbrushes to electric vehicles. But beneath the surface, a hidden world of quality control issues and dangerous counterfeits puts consumers and manufacturers at risk.

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1054

total 18650 battery cells CT scanned and analyzed for this report.

7x

lower quality anode overhang in low cost/counterfeit cells, a key indicator of process control.

50%

worse edge alignment in these same cells, which can accelerate degradation and lead to internal shorts.

33 of 1054

cells scanned had cathode overhang, a potentially dangerous defect that significantly increases risk of short-circuiting and catastrophic failure.

100%

of the 33 defective cells came from low cost/counterfeit brands.

1 in 13

or almost 8% of low cost/counterfeit batteries could have a potentially dangerous cathode overhang defect, based on this report’s results.

The Consumer Product Safety Commission (CPSC) consistently issues recalls and warnings due to battery overheating and catastrophic failures. While a low per-cell failure rate seems reassuring, the sheer volume of batteries in circulation means these risks compound dramatically.

Lumafield’s in-depth investigation shines a light on this critical issue. We CT-scanned over 1,000 18650 battery cells from 10 different brands, ranging from reputable OEMs to low-cost and outright counterfeit options.

Our automated analysis focused on key indicators of cell safety and quality, including anode overhang (AOH) and edge alignment, two critical factors that directly impact battery performance and safety.

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What we found was alarming:

Safety risks

All 18650s share the same 18 mm by 65 mm can, but safety lies in the jellyroll. CT lets us see anode overhang and edge alignment, the geometry that governs lithium plating and shorts.

Misrepresented specs

Sellers mimic trusted model names and wraps, then inflate specs. We documented listings copying Samsung’s 30Q branding and claims as high as 9900 mAh in a format that typically delivers around 3000 mAh.

Extreme outliers

Low-cost lots showed wide spreads and extreme outliers. Even when a brand’s median looked acceptable, many cells fell below the ~0.500 mm anode-overhang target and alignment varied much more than OEMs.

Detailed findings on battery quality across OEM, rewrap, and low-cost/counterfeit brands.
An in-depth explanation of critical battery components and their impact on safety.
Insights into the investigation methodology, including Lumafield's cutting-edge CT scanning and automated analysis techniques.
Recommendations for manufacturers and consumers to mitigate risks in the battery supply chain.

Learn how industrial X-ray CT can identify and help reduce hidden hazards in the lithium-ion battery supply chain.