Battery failures in consumer electronics are among the most consequential — and most complex — failures to investigate. A swollen cell may have failed due to overcharge, internal short circuit, separator degradation, or electrolyte decomposition, and each root cause has a different corrective action. At Aremac Labs, we apply a structured investigation protocol that combines electrochemical analysis, physical teardown, SEM and EDX characterisation, and X-ray imaging to identify what actually happened — not just what the failure looked like.
What we investigate
We investigate swelling and pouch deformation, thermal runaway events, rapid capacity fade, internal short circuits, electrolyte leakage, lithium plating, separator failure, BMS-related failures, and safety incidents involving fire or smoke. We work with cylindrical, pouch, and prismatic cells across consumer electronics, wearables, laptops, and EV applications.
Our investigation approach
Battery investigations require careful sequencing. We begin with X-ray CT imaging to assess internal structure without opening the cell, followed by electrochemical characterisation of remaining capacity and impedance. Physical teardown is conducted under controlled conditions. We then examine electrodes, separators, and current collectors using SEM and EDX to identify degradation mechanisms, contamination, or manufacturing defects that contributed to the failure.
Thermal runaway and safety incidents
If your product has experienced a thermal runaway event, fire, or regulatory incident, we can provide an independent technical investigation that identifies the initiating failure mode, the propagation sequence, and contributing factors in the cell design, BMS, or use conditions. These reports are structured for use in product liability matters, regulatory submissions, and insurance claims.
India-specific considerations
Ambient temperatures in India regularly exceed the upper operating limits specified in many cell datasheets. We see accelerated electrolyte degradation, faster SEI growth, and higher rates of capacity fade in devices used in Indian conditions compared to what manufacturers test for. Our analysis accounts for the actual thermal and charge-discharge environment your product operates in.