The Quality Gap

Behind the Battery Report

Behind the Battery Report Today, we released Lumafield’s Battery Quality Report, an investigation into the hazards that hide inside the lithium-ion battery supply chain. For this study, I CT-scanned 1,054 cylindrical 18650 cells from ten different brands, spanning the gamut from reputable, well-known battery manufacturers to ultra-discounted cells from Temu and several sources in-between. As battery users, we all intuitively expect alternative-brand cells to be lower quality, but it’s easy to gloss over how much worse they may really be, especially when a cheaper look-alike promises the same or better specs, and the name brands feel overpriced. However, our CT scans revealed much bigger quality gaps than I could’ve imagined, and once we factored in how dangerous a bad battery can be, the story turned from curious to genuinely concerning. Diving into battery quality questions As a Technical Product Marketing Manager at Lumafield, I design experiments to test and show how engineers can leverage CT to solve real problems. I’m constantly looking for areas to double-click on, and as a gadget-lover, batteries are all-too-often on my mind. A few months ago, I wrote a blog post about the Anker A1263 power bank recall, and it achieved a surprising level of virality given the relatively unglamorous product it covered. But perhaps the practical pervasiveness of batteries in all of our daily lives is exactly what drove so much interest in the piece. In that article, I scanned five power banks: enough to make a few concrete observations, but a tiny sample against the realities of production scale. I wanted the insights that could come with a larger dataset, and 18650 cells seemed like the obvious choice. 18650s are standardized battery cells, their name reflecting that they measure 18 mm in diameter and 65 mm long. These cells are absolutely everywhere. Over five billion are produced each year, and they can be found in everything from electric toothbrushes and cordless drills to even some electric vehicles. For example, each of the Anker power banks I scanned contained 3 18650s, and my colleague’s e-bike battery contained a whopping 39. Though the majority of 18650s are assembled into packs of multiple cells and deeply integrated into devices, there are a few applications where the cells are user-replaceable, such as vapes or flashlights, making them relatively easy to procure. Study methodology I ordered at least 100 cells from each of 10 brands, ending up with 1,054 cells total, given purchase increment minimums and free extras received. Every cell was scanned. Three sets came from the well-known OEMs—Murata, Samsung, and Panasonic—sourced from reputable online stores specializing in 18650 batteries. Three sets came from the rewrap brands Efest, Vapcell, and Trustfire, with Efest and Vapcell coming from reputable 18650 online storefronts, and the Trustfire cells coming from their brand website. The final four were more suspicious. I chose three of the brands for being lower cost: Treasurecase and Maxiaeon came from Temu, Benkia from Amazon. The SOOCOOL cells were not cheap, but were advertised on Amazon as “authentic” Samsung 30Q cells, their wraps closely but not perfectly mimicking the aesthetic of the genuine Samsung cells. A counterfeit SOOCOOL “Authentic 30QP” next to an OEM Samsung 30Q cell. Table of cells scanned for the experiment. Every battery was labeled on arrival for traceability, then scanned as received. We scanned on a Lumafield industrial CT system with a 130 kV microfocus source. Using Ultra-Fast CT, we scanned each cell in under a minute, then processed the data with our Battery Analysis Module, which automatically finds electrode edges and extracts study metrics in bulk. Lumafield has two industrial CT product lines: Neptune, a compact and easy-to-install solution ideal for R&D offices and labs, and Triton, optimized for high-volume environments. We built the workflow to reflect production realities, because annual battery output is enormous and speed determines practical value. In production, Triton paired with Ultra-Fast CT can scan cylindrical cells in under five seconds, enabling more than 720 cells per hour and making battery inspection feasible at scale. To support what we saw in the CT scans, I added a few supplementary tests. I measured capacity on one sample from each set. Marketing claims as high as 9,900 mAh appeared on some of the cell listings, a number that far exceeds what this format can deliver, and the measurements confirmed the mismatch. We also ran longer scans on a handful of cells to resolve more fine details and validate the automated measurements. Defining characteristics of battery quality The analysis focused on what governed safety. I prioritized three parameters for anode overhang and two for alignment. Median anode overhang per cell gave us a baseline for each brand. I used median rather than mean because a few extreme outliers would have distorted the averages. I also compared the maximum and minimum anode overhang values for each cell. Insufficient overhang increases the likelihood of lithium plating during charge, which accelerates aging and raises the probability of internal shorts. Alternatively, excessive anode length can reach the can and create a different short path. For alignment, we calculated the delta between the highest and lowest positions of both the cathode and the anode. Cylindrical cells are wound, and telescoping introduced during winding can become a seed for shorts and other defects. Large deltas point to weak process control and higher risk elsewhere in the line. Comparison of good and bad anode overhang. Side-by-side of ideal and suspicious edge alignment. Findings: Far more variance than expected The results aligned generally with our expectations, but the degree of difference was surprising. OEM cells showed tight control, with anode overhang centered near the 0.50 mm industry average and modest telescoping. The rewraps generally matched the OEM medians quite closely, though their spreads were wider, and the minimum overhang tails in particular stretched lower. Trustfire stood apart from Efest and Vapcell with a significantly worse distribution, a reminder that rewraps are blind boxes that carry real risk. Unless you scan and measure what you buy, you cannot be sure what exactly is hiding under the sleeve. The low-cost and counterfeit group was in a league of its own. Distributions were broader across every metric, and each brand in this tier produced at least one unit with negative anode overhang. The worst results came from the Temu brands. We found fourteen Treasurecase and fifteen Maxiaeon cells with cathode overhang. Across the entire low-cost group, thirty-three of 424 cells presented cathode overhang, which suggests that as many as one in thirteen such cells may carry geometry that accelerates aging and drives a higher chance of internal shorting. The standard deviations ran roughly seven times larger than the OEMs, which signals much weaker process control and, by extension, a higher likelihood of other hidden defects. Implications and recommendations These findings have implications for every stakeholder that interacts with batteries, from battery manufacturers and device integrators to end users. Original battery manufacturers prioritize quality, and the study results speak to their tight specifications and strong execution. The risk for these companies sits downstream, with scrap potentially making its way into the rewrap market, or OEM cells being “recycled” and resold when end-of-life devices are dismantled. Scrutiny of scrap procedures and channel partners, as well as improved traceability features, can protect these brands from being tarnished by the actions of less scrupulous players. Device integrators can reduce their exposure to dangerous batteries by validating their supply with incoming inspection, especially when buying through distributors or less established sources. Battery incidents can seriously mar the reputations of device integrators, making verification critical. Pack design is also essential to ensure battery safety, as building in sufficient spacing and protections can keep potential failures limited to a single cell. Consumers must also actively manage their individual battery risk exposure, given the gaps in supply chain and regulatory oversight. It’s important that users don’t mix brands, capacities, or ages in a shared device, that they protect cells from physical abuse and extreme temperatures, and that end-of-life batteries are recycled properly. Despite the popularity of “dupes,” when it comes to batteries, the savings aren’t worth the risk. Consumers should also familiarize themselves with the warning signs of battery incidents. Heat during or after charging, swelling or a soft feel, hissing, sharp chemical odors, discoloration, liquid residue, sudden drops in capacity, repeated shutdowns, or a charger that refuses to start all suggest internal damage. If you see any of these indicators, stop using the battery immediately and dispose of it at a proper facility. Parting thoughts Today’s volatile trade and tariff environment is complicating cell provenance more than ever, and it’s becoming easier and more attractive to slip gray-market substitutes into supply chains. In such a tumultuous ecosystem, CT becomes a practical tool for certainty. Our 754 non-OEM cells were mysteries until we scanned them, and while some matched OEM behavior, others fell far outside any reasonable specification. Most failures will never cause fires, but even a common reliability failure can disrupt the functionality and experience of a product. The rare battery incidents that do ignite are catastrophic, and this is why battery quality is so fundamentally important. Negative anode overhang and large irregularities in edge alignment do not guarantee failure, but they put a heavy hand on the scale in the wrong direction. Everyone who interacts with batteries, from cell manufacturers and device integrators to the people who use their products, should be intentional with managing these inherently dangerous devices. The Lumafield Battery Quality Report reveals the magnitude of risk in an uncontrolled battery supply chain. Industrial CT inspection allowed us to unearth the risky realities of the 18650 cells we ordered, by turning some of those key quality indicators into measurable geometry. Ultimately, CT is a powerful tool that can make the invisible visible by bringing much-needed clarity to the battery supply chain’s unknowns. SEO Meta Description: A closer look at the Battery Quality Report: methodology, surprising results, and what CT scanning uncovered inside low-cost lithium-ion cells. CT scans of 1,054 18650 batteries revealed major quality differences between OEM, rewrap, and low-cost cells, with defects concentrated in the cheapest brands. Negative anode overhang and poor alignment were key risks, raising the chance of internal shorts, accelerated aging, and thermal events. The study highlights supply chain vulnerabilities and shows how CT can give manufacturers, integrators, and consumers clearer visibility into battery safety.

Design to Reality

Building for the Brain: Pioneering a Long-Term Neural Implant

When you’re building an implanted medical device for the brain, you can’t cut corners. Engineering for performance is a given when you’re designing for a living system. To ensure that there are no adverse effects, an active implantable device cannot dissipate excessive heat, or there could be a risk to the surrounding tissue. Every decision, from materials, to power draw, and even packaging, is shaped by the need to do no harm. Designing a medical device is a totally different world from consumer electronics.Stakes of the SystemAt Paradromics, we’re building a brain-computer interface (BCI) to restore speech for people with severe communication disorders: conditions like ALS or spinal cord injury that disrupts the connection between intention and expression. Our first product, Connexus® BCI, records directly from the brain’s speech centers and synthesizes intended speech in real time.My focus as an electrical engineer is on the Cortical Module itself. That’s the component that sits on the surface of the brain, and it’s also the point where the technical demands are highest. The Cortical Module must be reliable, power-efficient, and manufacturable at scale. And it has to last a long time; because we are not interested in devices that require users to have brain surgery to replace their brain implant every two years as with some technologies being explored by others. Our goal is a device that never has to be replaced. That means every material choice and assembly step matters.People often compare implants like ours to wearable electronics, such as a smartwatch or continuous glucose monitor, as they share some similar goals: small size, clean data, minimal intrusion. But once you’re under the skin, everything changes. Now you’re dealing with strict FDA regulations, biocompatibility constraints, and failure modes with the highest possible stakes.Incompressible TimelinesSome timelines are just incompressible, and you have to come to terms with that. You can move fast in design, but once the project moves into manufacturing and validation, your pace becomes capped to that of regulation and biology. I wish someone had told me going into this field, that even with unlimited resources and engineering expertise, there are parts of the process you simply can’t speed up.Regulatory requirements shape design from day one. Connexus BCI is classified as a Class III medical device, the same category as a pacemaker. Implanted medical devices are typically limited to known biocompatible materials, and to support a minimum of a 10 year implant life that means materials like titanium, platinum, and gold. You can try to get new materials approved, but it’s a much longer road. And when you’re already working on a novel device, it’s wiser to avoid adding extra unknowns.Building the Plane While Flying ItThere’s no off-the-shelf playbook for what we’re doing. Our system isn’t life-supporting like a pacemaker, but it is life-enhancing. We work closely with the FDA to define safety and benefit to the patient for a device that doesn’t quite fit their existing categories. We’re being evaluated, while also helping define the rules.The metaphor we use internally is “building the plane while flying it.” It may sound chaotic, but it’s just the reality of working in a space this new. You have to keep moving forward, even while you’re clearing the path beneath your feet.Testing for the FutureThat pressure to get it right shows up most in testing. Our devices go through a long chain of inspection, step by step. Some processes require equipment so specialized there’s no commercial equivalent, meaning we have to do it ourselves. That’s why we use Lumafield's industrial CT scanner to evaluate process outcomes and observe internal structures that can’t be seen any other way. It’s one of the few tools that can keep up with the level of precision we need.In addition to testing in a large animal model, we also run accelerated aging tests, environmental stress simulations, and strenuous mechanical validation to make sure our devices can survive in the body for years. This includes checking for things like thermal performance, electrode durability, and even the consistency of raw materials from one vendor to another.Milestones That MatterThis work isn’t theoretical. Earlier this year, we completed our first human implantation in a patient undergoing unrelated brain surgery. The successful recording and data collection demonstration confirmed that our device performs well in the real world. We saw the kind of neural activity we expected and it validated years of animal studies and lab work. That milestone puts us on the path toward an Early Feasibility Study (EFS), a longer-term clinical investigation, where the device stays in place and is used regularly by a small number of participants. It’s the next big step toward FDA approval.Designed to StayI joined Paradromics right out of college in 2022, drawn to the cutting-edge intersection of engineering and neuroscience. It’s still a young field, and there’s so much left to figure out. But if we’re going to make a real difference for patients, we have to meet the body where it is. That means durability, reliability, and empathy for the people at the center of it all.This Cortical Module should feel less like a medical device and more like a part of someone’s life. If we can get there, we’ll have done our job.

Materials World

Comparing Wine Corks: Natural, Technical, and Synthetic

Corks have been critical components of wine preservation for centuries, with origins dating back to the 1600s. Derived from the bark of the cork oak tree, their elasticity and impermeability has made cork the reigning king of closures. Cork oaks thrive in Mediterranean regions, with Portugal producing over half of the world’s cork. Cork is harvested by carefully removing the bark without harming the tree (every 9-12 years), allowing it to regenerate and provide cork for years to come. Historically, cork’s unique structure has made it ideal for sealing wine bottles, but as winemakers seek ways to overcome issues like TCA (trichloroanisole) contamination and inconsistent oxygen ingress, alternatives like technical and synthetic corks have started to give natural cork a run for its money. How do these types of closures differ structurally? Our Microfocus Neptune industrial CT scanner gives us comprehensive insights into the composition and density variations between natural, technical, and synthetic cork. Let’s take a look.Natural CorkNatural cork is an organic material composed of layers of cell walls, primarily made up of the plant biopolymers suberin and lignin, which give cork its signature flexibility and impermeability. Below in our Voyager window, you’ll find our CT scan of the cork. It shows a 2D view of the cork's Z axis, and if you move the slider at the bottom of the window from the right to the left, you can follow the path of the corkscrew. You can toggle between 2D and 3D views by clicking the Cardinal Z ▼ button in the upper right corner of the window.Check out the scanThe blue regions in the reconstructions represent lower-density areas, while green and yellow are medium-, and red is higher-density. The faint lines running diagonally across the cork are growth rings. We can count 9 of them, representing as many years of growth.What about the higher-density matter? The characteristic speckled texture of cork stoppers is composed of holes called lenticels, porous structures in the cork bark that facilitate gas exchange. These openings lead to lenticular channels that are either empty or filled with loose parenchyma tissue, which allow for air movement. Surrounding these channels are higher-density cell walls (green-yellow in the scan), creating a more rigid border. This structure is critical for both the cork oak tree’s respiration and cork’s role in sealing wine bottles.Cork is always cut perpendicular to the grain to prevent the lenticels from creating direct channels through the cork, which could allow oxygen ingress. This orientation interrupts the lenticular channels with denser cork material, ensuring the cork remains impermeable and provides a secure seal for wine bottles.Controlled oxygen ingress through cork is beneficial for wine aging by allowing a small amount of air to interact with the wine and develop its flavors over time. However, inconsistencies in natural cork, coupled with the risk of TCA contamination (which can lead to spoiled, “corked” wine), have driven the industry to explore closure options that embrace advances in manufacturing technology.DIAM Technical CorkThe DIAM technical cork, first introduced in the early 2000s, was developed to address TCA contamination and inconsistent oxygen ingress in natural cork. In the DIAM process, natural cork is ground into granules and then blasted with supercritical CO₂ to remove TCA and other impurities that could affect the wine’s aroma. DIAM leverages the natural strengths of cork and preserves its sensory qualities without the liabilities that have always accompanied it.During production, the cork’s suberin—a highly elastic component—is separated from lignin, which is less elastic and discarded. The suberin is then combined with microscopic spheres (similar to those used in contact lenses), filling the voids between the cork particles and reducing porosity without increasing humidity. Our scan of a DIAM 5 cork (5 grade because it’s guaranteed for a minimum of 5 years) reveals a strikingly uniform structure, with an even distribution of both higher- and lower-density material that ensures reliable oxygen ingress and minimizes variability. The path of the corkscrew is clearer here, as the agglomeration process appears to have reduced the self-healing qualities of natural cork.Check out the scanThe suberin redistribution also enhances elasticity, guaranteeing consistent performance across all corks. By removing lenticels and controlling porosity, DIAM corks provide a reliable seal without the risks of TCA or inconsistent aging, offering a solution for wines requiring both short and medium-term aging. And once DIAM establishes a track record for the long-term aging of wines, we can expect to see it used more and more.Vinventions NOMACORC Synthetic CorkThe Vinventions NOMACORC synthetic cork, made using a patented co-extrusion process, consists of an inner foam core that controls oxygen ingress and an outer flexible skin for a tight seal. The skin even has a printed design to mimic natural cork’s growth lines and lenticels. In the scan, we clearly see the highly-porous core, and the corkscrew’s path is unmistakable.Check out the scanVinventions claims the corks guarantee highly precise oxygen ingress rates, with the NOMACORC Select Green 500 that we scanned rated for 3.1 mg of oxygen after 12 months, and then 1.7 mg yearly thereafter. This control provides optimal oxygen management for wines that benefit from more exposure earlier on in their aging process. Unlike natural cork, synthetic corks are immune to TCA contamination.Synthetic corks tend to allow more oxygen ingress compared to natural or DIAM corks, which accelerates the aging process of the wine. For wines meant to be consumed quickly, this may not be a major issue, but for those intended for long aging, the higher oxygen permeability could limit use of synthetic cork for high-end wines. The VerdictWhen comparing these three corks with industrial CT, we see a clear distinction in their structure and performance. Natural cork, with its organic variability, provides a time-honored but imperfect seal, subject to the risks of TCA and oxygen variability. Technical corks offer a reliable, consistent solution that mitigates the risks of contamination while maintaining the characteristics of natural cork. Synthetic corks provide durability and are free from TCA, but their higher oxygen permeability makes them better suited for wines with shorter shelf lives.In the end, the choice of cork depends on the winemaker’s goals and the intended lifespan of the wine. Natural cork remains an iconic choice for premium, long-aging wines, while technical and synthetic closures provide reliable alternatives for those looking to minimize risks and ensure consistency. With industrial X-ray CT, we can better understand a trajectory of design that began with nature and continues to this day as packaging engineers and winemakers seek to protect the quality of their wines without sacrificing the tactile charm of cork.Learn more: CT 101

Finding Lead in Stanley's Quencher

In a remarkable story of product innovation, Stanley became, in the words of its Global President Terence Reilly, a “110-year-old overnight success.” The company’s journey from inventing the first vacuum-sealed water bottle in 1913 to becoming a TikTok sensation began with the launch of the Quencher tumbler in 2016. The Quencher initially saw modest success, but a strategic shift in 2020 towards vibrant new colors and finishes caught the eye of a new generation of consumers. This pivot, coupled with savvy social media marketing and influencer collaborations, caused Stanley's revenue to skyrocket from $70 million in 2019 to $750 million in 2023.More recently, the same social media enthusiasm that propelled Stanley to new heights has revealed itself as a double-edged sword. Social media influencers have discovered that lead solder is used in the Quencher’s manufacturing process, jeopardizing Stanley’s success. But is the lead in the Quencher actually dangerous? Our Neptune industrial X-ray CT scanner is the perfect tool to see inside Stanley’s tumbler to understand how it’s made and whether or not lead solder truly poses a risk to consumers.Stanley’s cups have inner and outer walls made of stainless steel, separated by a vacuum that minimizes heat transfer. The manufacturing process for vacuum-insulated stainless steel containers starts by forming two separate stainless steel layers for the inner and outer walls, which are then welded together at the rim to create a sealed unit. The cup is placed in a vacuum chamber, and air is removed through a hole that’s left in the bottom of the outer layer.At this point, the hole through which air was evacuated must be sealed before the cup is removed from the vacuum chamber. Lead solder provides a reliable and cost-effective answer. During the assembly of the inner and outer layers, a small lead pellet is placed above the air-escape hole. After the air is pulled out of the cup, the vacuum chamber is heated just enough to melt the lead, causing it to flow into the air escape hole and seal it. When the vacuum chamber is opened, a vacuum remains between the cup’s walls.In our CT scans, we can clearly see the inner and outer stainless steel flask layers, as well as the solder point. We also see a metal disk attached to a welded tab, which may be a component used to position the solder and hold it in place before it’s melted. Dense materials or those made of elements with higher atomic numbers attenuate (absorb or scatter) X-rays more. Lead is very dense and tends to block X-rays, which is why it’s used to protect people from X-ray radiation. In Voyager, we’ve applied a color map to the reconstruction that corresponds to the range of material attenuation coefficients. Lead, the most attenuating, appears here as a solid red. The scan shows that the lead solder is completely shielded by a stainless steel cover just below it.Stanley issued a statement saying, “Once sealed, this area is covered with a durable stainless steel layer, making it inaccessible to consumers. Rest assured that no lead is present on the surface of any Stanley product that comes into contact with the consumer nor the contents of the product. In the rare occurrence the base cap of a product comes off due to ordinary use and exposes this seal, it is eligible for our Lifetime Warranty.” Leaded solder, despite its known health risks, remains widely used in various industries, including electronics, due to its superior workability and lower melting point compared to unleaded alternatives. The Stanley revelation has sparked a debate on the difficult trade-offs manufacturers face between continuing with a well-established but potentially harmful material or investing in the development of safer—albeit more expensive and technically challenging—alternatives.In response to the controversy, other reusable water bottle companies have been highlighting their lead-free manufacturing processes. Brands like Owala, Hydro Flask, and Klean Kanteen have successfully eliminated lead from their products, opting for alternative materials such as noncrystalline silica beads or proprietary sealants. These companies demonstrate that while the transition to lead-free manufacturing is complex and costly, it is feasible and aligns with growing consumer demand for environmentally friendly and safe products.As consumers become more discerning about the products they buy, the pressure on companies to not compromise on safety or sustainability will only increase. Perhaps just as important as continued innovation is educating consumers on the relative risks associated with materials and manufacturing processes. Proactively demystifying the product's lifecycle and design choices could mean the difference between soaring success and a viral backlash.

Materials World

From Rust to Silicon: A Week of Storage Media

Before storage vanished into silicon, it lived on film, glass, and metal. The moving parts and chemical coatings of these physical systems responded to specific engineering constraints and the demands of their respective moments. This week we use industrial CT to examine how five iconic formats worked, how they evolved, and why some still matter.Day 1: Magnetic TapeMagnetic tape appears outdated at first glance. It predates microprocessors, uses sequential access, and sits in silent racks. But it quietly stores much of the internet’s long-term memory. What explains its persistence?Tape began in the 1950s with mainframes writing data to reels of acetate or PET film coated in iron oxide. In the 1980s, home computers like the VIC‑20 used audio cassettes to store data as modulated tones, slow at 50 bytes per second, but accessible and cheap. Its survival comes down to physics and economics. Tape is a PET strip coated in magnetic particles, written to by aligning domains with a read/write head. It’s not fast, but it is dense, efficient, and durable.LTO, or Linear Tape‑Open, refines this idea. Cartridges use serpentine writing across dozens of tracks. LTO‑9 holds up to 45 terabytes compressed, with built-in error correction. Stored offline, these cartridges are immune to ransomware and accidental deletion.A 2024 report shows LTO shipments hitting 176.5 exabytes compressed, a 15 percent rise. IEEE Spectrum notes that tape, once written, uses no power and retains data longer and more affordably than disk or flash. As IBM’s Mark Lantz put it, “The technology hasn’t been frozen in time. Quite the contrary.”LTO remains the archival medium of choice for Amazon, Google, and CERN; it lasts up to 30 years under the right conditions. What may first look like legacy analogue tech turns out to be a refined archive engine designed for decades of reliable operation.Give the CT scan of the LTO a spin in our Voyager window above. Internal reels, guide rollers, and reinforced structures reveal a tightly engineered storage system designed for precision and longevity. Tape, it turns out, is built to last.Day 2: Floppy Disks and PocketZipFloppy disks made personal computing portable and practical. The first commercial version (the truly floppy one), released in 1971, was 8 inches across and held just 80 kilobytes. It paved the way for more manageable sizes. By the late 1970s, the 5¼-inch disk became standard for early home and business computers, offering between 360 kilobytes and 1.2 megabytes of storage.In the 1980s, a more durable format emerged: the 3½-inch floppy. Its rigid plastic shell (no longer physically floppy) and metal shutter protected the magnetic film inside, reducing dust contamination and physical damage. At 1.44 megabytes, it could store documents, program files, or even entire operating systems. These disks became a defining storage format for the personal computing era, remaining in common use into the early 2000s. Even today, the floppy icon still represents the Save function on many programs.Iomega’s Zip and PocketZip formats attempted to extend this logic. The original Zip disk reached 750 megabytes by the end of its run. PocketZip, launched in 1999, packed 40 megabytes into a cartridge roughly the size of a matchbook. Its performance was impressive for the time, but the format suffered from alignment issues and media wear. The rapid rise of USB flash drives and solid-state storage soon rendered it obsolete.In the scan of the 3.5-inch floppy, we see the dense, layered magnetic disk enclosed in its rigid plastic shell. The sliding metal shutter, which protects the media surface, is reinforced and spring-loaded. Also note the fine pitch of the read-write aperture and the minimal clearance between moving parts: tolerances that allowed reliable operation despite the format’s physical simplicity.Day 3: ROMBefore optical discs and downloadable software, ROM cartridges were the primary medium for consumer electronics. Popularized by consoles like the Atari 2600 and Nintendo Entertainment System (NES), these plastic modules held pre-programmed data on a silicon chip known as mask ROM. When inserted into a console, the system could execute software directly from the cartridge without the need to copy data into RAM.Each cartridge housed a printed circuit board, a ROM chip, and a set of exposed edge connectors. These aligned with spring-loaded contacts in the console, forming a direct electrical path. Unlike magnetic or optical media, ROM chips had no moving parts. They offered fast load times, physical durability, and built-in copy protection. But manufacturing was expensive, and the memory was fixed at fabrication.Many users remember blowing into the cartridge to fix loading issues. This ritual sought to remove dust from the contacts, but it was rarely effective and often counterproductive. Moisture from breath could corrode the gold or nickel-plated pins over time. The real issue was usually poor contact alignment or oxide buildup on the connector surfaces.Though cartridges faded as storage expanded and costs fell, they remain in use today in embedded systems and industrial equipment, where durability and immutability still matter.Our CT scan of a ROM cartridge shows the chip mounted directly to the PCB with clean solder joints and a rigid housing. The edge connector is precisely spaced, designed to maintain tight electrical contact even after thousands of insertions.Day 4: Magneto-Optical DiscsMagneto‑Optical (MO) discs blend magnetic and optical storage principles in a single hybrid system. Commercialized in 1985, they offered erasable, high-reliability storage long before affordable writable CDs appeared. MO media was typically 5.25‑inch or 3.5‑inch cartridges. The smaller version appeared in 1991 with capacities from about 128 MB up to 1.3 GB.MO writing uses a two-step process: a laser heats a magnetic film spot to its Curie point. A magnetic head on the opposite side then sets the domain orientation. Reading uses a lower‑power laser to detect changes in polarization caused by the Kerr effect. Time‑consuming though it was, verification after writing made it highly reliable and durable, with tens of millions of rewrite cycles possible.Enterprise archives like legal, medical, or media libraries looked to MO disks as a durable alternative to tape or early optical media. The cartridges physically protected surfaces from dust and fingerprints, and the media could tolerate temperature and humidity variations better than early CDs.Our scan shows a thick ferromagnetic recording layer enclosed in robust polycarbonate casing. The dual-side configuration leaves just enough room for both the laser window and precise magnetic write head spacing. The cartridge’s sturdy guide system ensures laser alignment and minimal contact pressure.Day 5: Hard Drives and Solid StateHard drives store data magnetically on spinning platters made of glass or aluminum, coated with cobalt alloy or iron oxide. Read and write heads hover nanometers above the surface to flip magnetic domains as the platters rotate. Consumer drives typically spin at 5,400 or 7,200 RPM. Multi-platter setups allow higher capacity by stacking more heads and surfaces in a compact enclosure.These drives helped shape modern computing, offering fast random access and low cost per gigabyte. But they are vulnerable to shock, wear, and latency limits.Solid-state drives replaced moving parts with NAND flash memory. Floating-gate transistors retain charge without power, enabling fast, shock-resistant, and silent operation. SSD controllers manage data distribution, wear leveling, and error correction. NVMe models use direct PCIe access to deliver transfer speeds beyond 7 GB/s.SSDs have grown rapidly in both performance and reliability. According to Ars Technica, five years of data from Backblaze show that SSDs fail far less often than hard drives over time.The CT scan of a Lite-On SSD shows NAND packages arranged around a central controller. You can see dense surface-mount components, multi-layer routing, and clean solder joints.Storage for PosterityIf future engineers scanned today’s storage media a hundred years from now, what would they learn about how we valued information?Over five days, we examined storage formats that shaped computing: tape, floppy, ROM, optical, and solid state. Each one reflects tradeoffs between speed, cost, permanence, and complexity.Industrial CT shows these are not just passive containers. They are engineered systems, often with precision far beyond what their plastic shells suggest. Even the most outdated format holds clues about the priorities and constraints of its time, saying as much about us as the data it holds.

Design to Reality

Heinz’s Sustainable Ketchup Cap

Heinz has taken a major step forward for sustainable packaging with the introduction of its first fully recyclable ketchup cap, made possible through a pioneering collaboration with Berry Global. Combining complex engineering with simple materials, Heinz’s achievement offers a model for manufacturers in consumer packaged goods (CPG) as well as food and agriculture at large to strive for waste reduction by designing more environmentally-friendly products.Industrial CT is the perfect tool for exploring the intricacies of Heinz's new cap design without damaging it, even while it’s fully assembled and closed. Let’s take a look.Mono-material constructionThe old cap featured a silicone valve, which posed recycling challenges. The new cap's uniform composition of polypropylene (PP) simplifies recycling and can be accepted by any facility that processes plastic #5. Currently only about 3% of PP products are being recycled in the United States, but it is becoming more widely accepted. The new cap appears as a uniform color in Voyager’s range map, indicating that it’s entirely made of the same material. Compare it to the old cap, whose silicone valve is denser than the surrounding plastic.The dense silicone ring (left) presents obstacles for recycling. The new mono-material cap (right) is of a uniform density.Innovative valve designThe new design leverages ketchup's shear-thinning property to dispense the perfect amount. Ketchup requires a specific amount of pressure to flow. When the bottle is squeezed, it moves through the outer channels where the wall separating them from the inner channels plays a crucial role. The wall prevents the ketchup from flowing back and directs it toward the antechamber, building the necessary pressure for the ketchup to pass through the nozzle efficiently.Once the squeezing stops, the ketchup's viscosity increases, preventing drips and mess. This design ensures a clean and controlled dispense of the product.Views from below (left) and above (right) of the Heinz ketchup cap's valve channelsIndustrial CT and sustainabilityDeveloping sustainable packaging can present a significant engineering challenge. Recyclable plastics often don’t perform as well as their non-recyclable counterparts, and reducing material usage can mean that safety factors are reduced as well. Effective, sustainable packaging requires careful design and lots of fine tuning.Industrial CT plays a pivotal role in the development of sustainable packaging, offering a non-invasive method to analyze, refine, and perfect packaging solutions. By reducing the need for physical prototypes, CT scanning accelerates the development process, cuts down on waste, and helps avoid the costs associated with scrapped prototypes and recalled products. It embodies the convergence of innovation and sustainability, offering a blueprint for the packaging industry's next steps.Advanced Surface Capture technology can help manufacturers tell the whole story of their sustainability efforts by visualizing areas that are otherwise impossible to capture—those hidden by overhangs as well as shiny and reflective surfaces.Heinz's recyclable cap is more than just an innovation; it's a statement of intent, reflecting a broader commitment to environmental sustainability. The cap's successful redesign, fueled by a $1.2 million investment and extensive testing, demonstrates the potential for significant waste reduction—up to 300 million plastic caps annually—and a future where packaging is fully recyclable, reusable, or compostable.Learn moreDownload our free white paper Removing Obstacles to Sustainable Packaging and discover how industrial x-ray CT can help packaging engineers create solutions that work.

Design to Reality

How Does a Car Cigarette Lighter Work?

Remember this? Cigarette lighters were universal accessories in cars until the mid-1990s. We put one in a CT scanner to see how it works and discovered a marvel of efficient, low-cost analog design.Check out the video below to see the cigarette lighter in action and walk through the CT scans with us:An analog systemA cigarette lighter in a car connects to a 12V DC power supply. To heat it up, you press the handle in. It starts to draw current, and after a few moments, the handle pops up, revealing a glowing coil hot enough to ignite a cigarette. You might think such a system would involve a thermostat, a microcontroller, and an actuator, but this design, developed in the 1950s, is entirely analog and optimized for simplicity and cost-efficiency.Type image caption here (optional)Examining the CT scansWe used a Neptune industrial CT scanner to capture detailed scans of the lighter. This scanner works on the same principle as a medical CT scanner, capturing X-ray images from different angles and reconstructing them into a 3D model.Lighter in the popped-out positionIn this scan, the lighter assembly is in its popped-out position, as it would be after heating. By stripping away the less dense plastics, we isolated the metal components for a clearer view.Give the lighter a spin for yourself in the Voyager window below:Cutting into the model, we see the removable lighter with a large bolt fixing the plastic handle. Surrounding the handle is a single coil spring. The heating element is visible in the center, with another bolt below it attached to the arms of a spring clip. The coloring indicates relative material density, showing stamped steel and a ceramic insulator around the lower bolt.Lighter in the pushed-in positionNext, we examined the lighter after the handle has been pushed in, simulating its heating configuration. The heating element is held in place by the spring clip, creating a circuit.In a car, the bottom bolt connects to a positive lead, and the housing tab connects to a negative lead. Current flows through the isolated bolt, the spring arms, the outer rim of the heating element, the heating coil, the center bolt, and finally back to the negative terminal. The current is forced through the high-resistance coil due to a tiny gap insulated by a strip of paper, preventing it from taking a shorter path.Detail: Heating elementA closer look at the heating element reveals its design. The coil, made of nickel-chromium alloy, is bonded to the surrounding shield on one end and the center bolt on the other. Each loop is oxidized, insulating it from adjacent loops and forcing the current to traverse the entire resistive filament.Pop-out mechanismThe spring clip, which holds the lighter in its depressed position and conveys current, has bimetallic arms with steel on the outer surface and copper on the inner surface. As the filament heats up, the arms warm up, causing the copper to expand faster than the steel. This expansion pushes the arms open, releasing the lighter. The coil spring then causes the handle to pop out, signaling that the lighter is ready.ConclusionThis entirely analog device, developed in the 1950s, showcases the ingenuity of efficient, low-cost design, capable of being manufactured by the millions without any digital control.You can explore these scans yourself in the Voyager. If you’d like to learn more about industrial X-ray CT technology and how engineers use it to improve everything from running shoes to medical devices, check out our introductory video or reach out to our team.

The Quality Gap

How People Drive Quality

When people think about quality in manufacturing, they often think of documentation like certifications, processes, and forms. That stuff definitely matters, but it’s not the core of it. What really drives quality is people: how they work, how they think, and whether the system around them helps them succeed or sets them up to fail. That’s the lens I brought to Lumafield after working in medical devices, where the bar for quality is high, and for good reason. What Medical Devices Taught Me About Quality Before Lumafield, I worked in a highly regulated environment under ISO 13485, which is the quality standard for medical device manufacturers. In that world, trusting that someone made a good product isn’t enough; you have to prove it, every step of the way. What’s interesting about medical device manufacturing is that it doesn’t control the certification of the individuals designing a product, like the certified PE (Professional Engineers) in civil engineering. Technically, anyone can sketch out a medical device. What the certification does control is how that product gets built and tested. That means heavy documentation: from ideation and risk analysis, to design verification and validation, to production release and traceability. Every requirement needs to be documented, and every product needs to be tested against those requirements, with a full paper trail to back it up. I spent a lot of time in that system, and while some parts felt rigid, it also taught me how robust a good quality system can be. Every step exists to build confidence, minimize risk, and create repeatability. That experience gave me a foundation for how I think about quality now, even in a startup where we don’t have formal certifications (yet). What Quality Looks Like at a Startup At Lumafield, we’ve had to figure out what quality means without that external structure. We go beyond the safety standards our product is certified for, despite it not being required. Because even without a certifying body breathing down our neck, we care about building reliable products, and we know that just “building it right the first time” doesn’t scale. So instead of a formal QMS, we rely on a culture where every individual with hands on our hardware cares about product quality, and we enable those individuals with practical implementations of the bread-and-butter tools of manufacturing: detailed work instructions, in-process checks, and a responsive NCR process. Our focus is always on improving quality where the action is happening, not somewhere buried deep in a stack of SOPs. We want our operators to have the tools and information they need to reliably build quality products safely. That sounds simple, but we’ve come a long way since we started. When I joined, there was no structure yet—no standard for how instructions were written, no consistent way to track build issues, no process for root cause analysis. We’ve built that all from the ground up. What We Catch, and When Ideally, we’d catch every problem before it gets to the floor. That’s the goal with things like first article inspections and incoming quality checks. But at this stage, with how lean our manufacturing team is, we’ve had to make strategic tradeoffs. We can’t inspect every part, so we need to take calculated risks on where it’s more efficient to catch issues later on the production line and where we need to spend the resources to catch issues upon receipt. It’s a burn rate we accept. We’ll pay a little more for extra parts or expedited shipping if it means we can stay flexible and move quickly to meet our customer’s needs. Eventually, that’ll change. As we scale, it’ll make more sense to increase our investment in prevention. But right now, we pick our battles. Some parts are high-risk or high-cost, and we’ll spend the time checking those. Others, we let go and monitor downstream. That balance will keep shifting as we grow, but our culture where everyone, every step of the way, is invested in making quality products will remain the bedrock of how we build our hardware. Helping Build Techs Check Their Work One thing we’re pushing on with Triton is giving our build techs the ability to check their own work earlier. Right now, they’re really good at understanding how parts go together, because good mechanical design communicates that on its own. But when we get into more complex subsystems, like motion platforms wrapped in shielding and packed into tight spaces, things get murky. If it doesn’t work at the end, there are too many places to look. Instead of having our technicians blindly checking off items on a list, we’re building in subsystem testing to enable them to “check their own work” and learn from their mistakes. If we can test a motion platform before it’s wrapped up in the system, we isolate any issues and fix them while things are still accessible. It’s a huge time saver, and it makes debugging much more predictable. Designing Quality In The biggest factor that enables us to take this practical approach to quality is the thought that goes into the design of our hardware products. As Murphy’s Law states “if something can go wrong, it will”. In hardware that means if a part can be installed incorrectly, it will be installed incorrectly. It’s just a matter of time. That means the right move is to design the part so that incorrect isn’t possible. That may sound like just common sense, but it’s actually a core principle in any good quality system. At Lumafield, our hardware engineers live this mantra by heavily prioritizing getting hands-on with what they design. They’re on the floor turning wrenches, seeing what’s intuitive and what isn’t, and quickly making improvements. That feedback loop is gold. It mitigates all but the most manageable risks so that our manufacturing team is set up for success. It allows us to continue manufacturing consistent products as the people and the production environment change. Systems, Not Just Screws At Lumafield, we’re building scanners. But more importantly, we’re building the system that builds the scanners, and it’s a system that will have to scale, adapt, and improve over time. That’s why we’re hiring more manufacturing engineers now. Not to turn screws, but to support the whole process: the practical tools and the problem-solving systems that make it possible to build the same thing well, over and over. That’s what quality really is. Compliance and control are just the beginning. What matters most is taking pride in the little things that bring joy to your customers. It’s about making right-sized solutions so those on the front lines can do their jobs well and get better over time. All too often, manufacturing teams lose sight of this; getting the paperwork/documentation right starts to overshadow getting the product right. Only through thoughtful systems, good design, and people who care can you consistently deliver quality to your customers.

Inside a 12‑Month Sprint from Concept to Factory‑Ready Product

Parts Under Pressure

Materials World

Speaking in Steel and Sapphire: MING’s 20.01 Series 5

In watchmaking, every material shows up in the final product. You see it in the way light moves across a dial, feel it in the weight of the case, and hear it in the click of a pusher. With our S5 chronograph, the materials arose from years of persistent trial and error, testing what works both technically and aesthetically. MING is a small independent brand. We design and develop everything in-house in Kuala Lumpur, then work with specialist partners in Switzerland and elsewhere to build watches in limited batches. The S5 is our flagship chronograph. It’s a maximalist piece meant to push every part of the design, movement, and materials as far as we could take them. I’m not a trained watchmaker. My background is physics, finance, and photography. But eight years in this business has taught me one thing: you don’t survive by doing what everyone else is doing. Materials are part of that challenge. Over the years, we’ve worked with titanium, tantalum, magnesium alloy, and more. Each one changes how a watch looks, feels, and wears. The S5 is a distillation of that experience. Inside the Movement A movement is mostly brass; it’s stable, easy to machine, and fine detail holds well. Steel takes on higher-wear jobs. Bearings are synthetic ruby, which are both hard and consistent. Some parts need specialized alloys. The hairspring is Nivarox for temperature stability. The balance wheel is made from a similar alloy to hold its moment of inertia. For the S5, we started with a complex chronograph from Agenhor and reworked it. We reshaped the bridges and refinished the surfaces. Earlier models had a gradient of DLC coatings across the layers. They’re small details, but they add depth. The Case Normally a watch case is built like a can: the movement sits inside a middle ring, the bezel goes on top, and the case back closes from the bottom. The S5 is different. Because I wanted integrated lugs with hollows, the case had to be split in an unconventional way. The movement sits inside a donut, the lugs attach from the sides, and the bezel and case back come in from the top and bottom. The seams are hidden in 90-degree orthogonal divisions, so you don’t actually see where it comes together. Four pillars integrated with the bezel hold the whole thing in place, which means the watch uses about half the number of screws you’d normally need. In fact, it stays together without screws at all. They’re only there to lock it down at the end. Weight and Performance Weight in a watch is a choice. You can make it much lighter than it looks, or much denser. That contrast between what you expect and what you feel makes an impression. But it’s not just perception. A mechanical watch runs 24/7, beating three to five times a second. Tolerances are so tight that if one jewel in the escapement is off by 10 microns, the whole thing stops. Materials have to survive that workload, stay dimensionally stable, resist corrosion, and be safe against skin. Every alloy and coating is chosen because it can do that and still deliver the feel we want the moment you pick it up. The Dial The S5 dial starts as a single billet of titanium. We laser and micro-machine it to create fins and facets, then apply a blue PVD coating. After that, it’s lasered again to bring out additional detail. The result is a layered surface that shifts depending on the light. We knew we wanted contrast in the different finishes, colors, and textures to control how light hits the dial. Some of it is determined by what a material will accept. Titanium takes certain surface treatments that steel won’t. Sapphire, on the other hand, can be etched in layers. We prototype, assemble, and decide by eye. Engineering White Lume Standard lume colors are fixed by the dopants in strontium aluminate: blue, green, yellow, orange, and pink. True white needs mixing across the spectrum, but each dopant has its own brightness and decay rate. The blend that looks white to the eye is uneven—heavily weighted toward some colors, reduced in others—and has to stay white as it fades. We kept adjusting until it worked. That’s how we achieved the S5’s Polar White lume. What’s Next We have more than a hundred projects in the works. Some use metals never seen in watchmaking. Others involve multi-phase color-shifting coatings, seamless transitions between metal and sapphire, interference patterns, and animated effects. All of it is about how materials behave and how to make them do something new. For me, materials are so much more than just the medium. They’re at the heart of watchmaking as a pursuit. The S5 speaks in steel, titanium, sapphire, and light. Every part of it is chosen for what it brings to that conversation.

Stored Energy Meets Soft Spots

The Secret to Better Running Shoes? CT Scanning

When it comes to running, comfort is king. A shoe that doesn’t fit just right—whether it’s too tight, too loose, or blister-inducing—can mean the difference between a personal best and a painful run. But creating a shoe that delivers comfort, durability, and performance at scale is a challenge when so much of its structure is hidden from view.For Luca Ciccone, Director of Product Engineering at Saucony, understanding a shoe’s structure has always been as important as its materials. Industrial CT presented a new way to do just that—offering insights that traditional inspection methods simply couldn’t. When Saucony began working with Lumafield’s Neptune CT scanner, it quickly became an essential tool in their development process. Now, their engineers can examine every layer of a shoe without cutting it apart, allowing them to spot hidden flaws, ensure consistency, and fine-tune designs before they ever hit the production line.CT scanning isn’t just for elite racing shoes; it’s a tool that improves footwear for every kind of runner. That’s why we sat down with Luca to take a look inside a comprehensive range of Saucony’s shoes, from the Omni 9, a stability-focused trainer for everyday wear, to the Ride 18, a cushioned workhorse built for long miles, and the Endorphin Elite 2, an elite marathon racing shoe.Comfort vs. PerformanceTo engineer a comfortable shoe, designers have to thread the needle between a reliable hard good and a comfortable soft good. That means looking at more than just materials and construction methods—it requires a deep understanding of how every individual component interacts with the rest of the shoe.Being able to see the CT scan and digitally cut the shoe in half to look at each one of the components and how everything came together, we can truly understand the consistency that we’re getting in our R&D phases, all the way up into production.‍That insight is crucial when working with intricate, multi-layered products like running shoes. Even a small misalignment—like a heel counter being placed slightly off-center—can change the way a shoe fits and feels. And because runners expect every pair to feel the same, maintaining consistency is just as important as getting the initial design right.“If it’s misaligned in any way, shape, or form, it can truly affect the comfort of the shoe and how it can perform,” Ciccone explained. “We want to make sure that we’re minimizing these risks upfront.”Saucony’s Omni 9While the Omni 9 may look like a casual, fashion-forward sneaker, there’s a surprising amount of engineering beneath the surface. The shoe is designed to provide both comfort and stability, but that balance depends on careful placement of key internal components.One of the most important of these is the heel counter—a rigid insert that helps lock the foot in place. Because it sits inside the shoe’s upper, it’s impossible to inspect without cutting the shoe open—unless you use CT scanning.“The first thing that I look at when I look at a CT scan of this particular shoe… is where the heel counter is being placed on the inside of the upper,” Ciccone notes. “You cannot see it from the outside, and the only way that you’re able to look at it is by cutting it in half.”With CT scanning, Saucony can go beyond simply verifying placement. Engineers can measure its exact position, assess alignment across different production batches, and ensure it maintains its shape under stress. This level of detail helps eliminate inconsistencies before they become comfort or performance issues, keeping every pair true to its intended design.Saucony’s Ride 18A great running shoe isn’t just comfortable on the first run—it has to feel just as good after hundreds of miles. That’s why the Ride 18 was designed with durability in mind. But materials alone aren’t enough to guarantee longevity; the way they’re assembled matters just as much.Sometimes, issues don’t appear right away. A runner might wear a pair of shoes for weeks before noticing that a certain spot feels less cushioned than it used to. These breakdowns are often caused by inconsistencies in glue application, foam density, or structural bonding—issues that aren’t visible from the outside.If you’re able to look at all of your products throughout testing, you can simply see where those breakdowns occur, and you’re able to fix the design down the road.‍Saucony’s Endorphin Elite 2Saucony's brand-new Endorphin Elite 2 is built for speed, and its performance hinges on the precise interaction of multiple components. At the heart of the shoe is a carbon-fiber plate sandwiched between layers of PWRRUN PB foam. This plate helps propel runners forward, but only if it’s positioned perfectly.Our scan of the Endorphin Elite 2 shows the way the foam and carbon plate have been bonded together. If there were any air pockets, inconsistencies, or shifts in placement, they would be visible in the scan—allowing the team to refine the process before production.CT scanning lets Saucony detect potential weak points before a shoe ever reaches a runner’s feet. By analyzing the bonding between the midsole and upper, the adhesion of different materials, and the uniformity of the foam, engineers can make adjustments that prevent premature wear and tear.The Future of FootwearCT scanning isn’t just a tool for defect detection—it’s a new way of thinking about product development. For Saucony, that means fewer prototypes, more reliable manufacturing, and better-performing shoes. Instead of relying on assumptions and best guesses, the team can use real-world data to make informed decisions at every stage of the design process.As engineers, we always strive to make our products better. Being able to look inside our shoes without cutting them apart—that’s a game-changer.‍From stability-focused trainers to elite racing shoes, every model in Saucony’s lineup benefits from precise, data-driven engineering. And thanks to Lumafield’s CT scanning technology, that engineering is more accurate, efficient, and effective than ever before.

Too Hot, Too Sharp, Too Loose

The Quality Gap

What Went Wrong Inside These Recalled Power Banks?

Lithium-ion batteries power the many electronic devices that we rely on every day, from EVs to smartphones and laptops. They’re so prevalent, that the average American owns nine lithium battery-powered devices.1 But they carry real risks when quality lapses occur. Overheating and fire hazards can cause property damage, injuries, or worse. With millions of these batteries in circulation, even a single defect can have a ripple effect of consequences for consumer safety and brand reputation. Recently, Anker recalled over one million PowerCore 10000 power banks, model A1263, produced between 2016 and 2019 and sold through 2022.2,3 Anker has provided a general warning that the lithium-ion battery can overheat, but they have yet to share the exact reason for the recall. Armed with our Neptune Industrial CT Scanner and five A1263 power banks from Lumafield team members, we set out to see if we could identify the source of this recall. Could we identify the defects with CT scanning? And could CT inspection during development or manufacturing have prevented the faulty power banks from shipping in the first place?Scanning SetupWe procured five potentially-affected power banks from various Lumafield colleagues, which we labelled PB1, PB2, PB3, PB4, and PB5. We then ran the serial numbers against Anker’s recall form, and determined that three of our power banks were impacted, while two were not.The power banks were scanned using Lumafield’s Microfocus Neptune. This configuration’s small X-ray spot size makes it the ideal tool for resolving fine details in electronics and batteries.4Use the embedded Voyager window below to explore the CT scan of the recalled power bank. Rotate and examine it from any angle.First Look: Battery CellsThe first element we compared across the power banks were the battery cells themselves. A lithium-ion battery consists of two separated electrodes. The anode, usually graphite, stores lithium ions during charging. The cathode, typically a layered metal oxide, releases and accepts lithium ions as they move through the electrolyte during charge and discharge, enabling reversible energy storage.There are a few common defects in the battery manufacturing process that can be easily spotted in a CT scan. For example, in lithium-ion batteries, it’s important to ensure that the anode has a sufficient overhang above the cathode, preventing the lithium plating that can lead to dendrite formation.5 Dendrites can subsequently result in degraded performance and short circuits, which can cause the worst-case scenarios of thermal runaway. CT scanning can also be used for Foreign Object Detection (FOD) within batteries, as particle contamination can lead to reduced performance and potentially short circuits.The A1263 power banks each contain three 18650 lithium-ion battery cells inside. It was quickly apparent that batteries from at least two different suppliers had been used within the affected power banks. The cells in PB1 (recalled), PB2 (recalled), PB4 (not recalled), and PB5 (not recalled) seemed similar, but the cells in PB3 (recalled) had a few key differences. First, the batteries in PB3 have a mandrel to help prevent core collapse, a type of deformation in lithium-ion batteries with “jelly roll” construction where the innermost layers can sag into the center.6 Mandrels can also serve as a pathway for gas escape in case of overpressurization. Some suppliers add a center tube to strengthen the core and prevent this from happening. Though none of the batteries in the five power banks we scanned seem to show core collapse, only PB3 has reinforcement material to combat this potential issue.On the left cell, from PB3, reinforcement foil appears as bright, dense material around the battery’s center. This is noticeably absent from the right cell, from PB1. The other discrepancy in the PB3 batteries is the number and style of vent openings. PB1, PB2, PB4, and PB5 have four smaller openings at the positive terminal, while the PB3 cells have three larger ones. This further suggests that the batteries in PB3 come from a different source.In the left image, we observe 3 vent openings from a cell in PB3. In the right image we see the four vent openings common across the cells in PB1, PB2, PB4, and PB5. If the recall is affecting units made with 18650 battery cells from multiple suppliers, that suggests the root cause of the recall stems from elsewhere in the power bank. We next focused on the PCB and assembly of the board with the cells.Assembly Discrepancies Looking at the assembly of the A1263 power banks, one difference between the recalled and non-recalled devices stood out immediately. All five power banks used tab bus bars to connect the positive and negative terminals of the 18650 cells. However, the non-recalled PB4 and PB5 devices used conventional insulated wires to make the positive and negative connections to the PCB, while the recalled PB1, PB2, and PB3 power banks used flat tab wire for the entirety of the connection.On the left image of PB4, thin insulated wires are clearly visible. On the right image of PB2, wide thin tabs are used for the connections instead.‍A closer look at the connections between the cells and PCB in PB4 (left) and PB2 (right).Looking more closely at the connections of PB1, PB2, and PB3, we see some process variation that could be a potential cause for concern. The shape of the negative tab differs dramatically, and in PB1 it appears slightly twisted. From left to right, the negative tab crossing above the positive tab - PB1, PB2, PB3.We can measure the distance to quantify how dramatically the gap between the positive and negative bus bars varies across the three units. In PB1, that distance is only 0.52 mm, compared to 1.12 mm in PB2 and 1.58 mm in PB3. The short distance and visible deformation in PB3 suggests the possibility of the negative bus bar shorting out against the positive bus in some scenarios.From left to right, measurements of the space between the negative and positive tabs for PB1, PB2, and PB3.Evolving Power Bank DesignIn addition to the recalled power bank, we scanned Anker’s current PowerCore 10000 model, the Anker 313. This model was first released in January 2023. The exterior of the power bank has changed significantly. At 5.87 in by 2.68 in by 0.55 in,7 compared to the A1263’s dimensions of 3.62 in by 2.36 in by 0.87 in,8 the 10K product has become longer and wider, but also noticeably thinner. Looking inside, we find this slimming has been accomplished by replacing the three 18650 cylindrical cells with a single lithium-ion pouch cell. With 90-95% packaging efficiency, pouch cells are maximally compact relative to other battery cell designs and can be customized to accommodate different industrial design requirements.9 The single-cell configuration of the Anker 313 simplifies the assembly required. We also see that significant changes have been made to the embedded electronics, as is to be expected given both the new product architecture and the general advances in PCB manufacturing since the A1263 was manufactured.CT scan of the updated Anker PowerCore 10000, showing the single lithium-ion pouch cell and a slice of its PCBA.ConclusionCT scanning the A1263 Anker PowerCore 10000 power banks has provided a small window into the supply chain complexity of these pervasive, ostensibly simple products. This SKU was manufactured over a period of 3 years and 10 months, and sold for over six and a half years. From our limited analysis of just five power banks, a small subset of the millions of devices sold, we have identified that throughout the A1263 production period at least two battery cell versions and two battery connector designs were used. A larger sample size would likely reveal further variations. Managing a high-volume battery supply chain is inherently challenging, and ensuring quality throughout each stage is essential. Only Anker can know for sure why these popular consumer devices have warranted a recall three years after they were last sold. However, though we don't know exactly what flaw triggered this massive recall, it illustrates just how costly quality issues can be. The volumes involved in these types of consumer products can be staggering, and it can be extraordinarily difficult to track quality issues all the way upstream. Since we began this exploration, Anker has issued a new recall for five additional power bank models: Anker Power Bank models A1257 and A1647, Anker MagGo Power Bank model A1652, and Anker Zolo Power Bank models A1681 and A1689.10 Unlike the A1263 Anker PowerCore 10000 power banks, these are more recent products. Anker has shared that the recall was caused by potential issues with one of their battery suppliers. Their English announcement credits the more rigorous quality processes they implemented earlier this year with catching the cause for concern,11 while announcements in China by Anker and competitor ROMOSS Technology disclosed that the cell supplier in question made an undisclosed change in the raw materials used, which could lead to insulation degradation.12 Anker has recalled 710,00 units from those models in China, and the global numbers have yet to be disclosed. Looking just at the recall of A1263 Anker PowerCore 10000 power banks sold between 2016 and 2022, about 1,158,000 units have been affected. Impacted users will receive either a replacement unit or a $30 Anker Store gift card, implying a financial exposure of over $34 million, not including other relevant recall-related costs. Beyond the immediate economic impact, battery recalls can cause permanent reputational damage that proves impossible to quantify in the long term. Anker has underscored their commitment to better quality assurance processes and signed an agreement with a new battery vendor13 as they work to regain the trust of their customers.Industrial CT inspection offers a powerful tool that can help ensure the safety of the many battery products that surround us. It can be leveraged during the design and development stages to validate designs and brought into the manufacturing ramp-up to support First Article Inspection and validate assembly processes. In production, it can non-destructively verify quality, both upstream and downstream. And after parts have shipped, CT scanning can be used to support faster failure analysis as issues arise in the field. Ultimately, ensuring the reliability of lithium-ion battery products is becoming more critical than ever, as these devices become increasingly embedded in our daily lives. As CT inspection becomes more accessible and easier to adopt, it can serve as a safeguard of both consumer safety and manufacturers’ bottom lines.

The Quality Gap

What’s Inside Your Water Filter? A CT Scan Comparison

Water filters are our silent guardians, protecting us from a whole host of invisible contaminants. But what’s happening inside them as they work tirelessly to deliver clean water? With industrial CT scanning, we can take a detailed look at the internal structure of water filters—before and after use—to uncover how they perform, age, and ultimately safeguard our health.In this deep dive, we’ll explore four types of water filters: pitcher filters, refrigerator water filters, reverse osmosis filters, and the LifeStraw. By getting to know their inner workings, we can see how each design contributes to its effectiveness and how they handle the wear and tear of daily use.Pitcher Water FiltersPitcher filters are household staples, using a blend of activated carbon and ion-exchange resin to trap impurities such as chlorine, sediment, and heavy metals like lead. When water passes through, the carbon absorbs contaminants, while the resin removes specific ions to improve taste and safety. Type image caption here (optional)A CT scan of a new pitcher filter reveals a porous, uniform core of activated carbon and resin. The material’s consistency ensures even water filtration throughout the cartridge. After use, however, the scan tells a different story. Clearly-defined flow channels are visible, suggesting that water is following the same path through the filter media each time, limiting the thoroughness of filtration. The once-pristine pores are partially blocked by accumulated sediment and impurities, and denser particles have migrated to the outer edges of the core—indicators that consistent, uniform filtration is a thing of the past for this particular filter.Refrigerator Water FiltersRefrigerator water filters deliver clean water for drinking and ice, and we barely notice them because they are directly connected to a water line. These filters rely on dense activated carbon cores enclosed within sturdy plastic shells.In a new refrigerator filter, CT highlights the robust, porous structure of the carbon core. This setup is ideal for trapping particles, chlorine, and even some volatile organic compounds. Over time, as the filter absorbs these impurities, the core grows noticeably denser as the filter absorbs contaminants day in and day out. Initially, the plastic casing was the densest element, but after months of use, the filtration media becomes markedly denser than the outer shell. Reverse Osmosis Water FiltersReverse osmosis filters take water purification to the next level, using a semi-permeable membrane composed of tightly wound layers of synthetic material. These layers create microscopic pores that allow water molecules to pass through while blocking contaminants like salts, minerals, and chemicals. The membrane is often supported by a mesh or fabric backing and enclosed in a cylindrical housing for durability and ease of installation. Reverse osmosis systems are the go-to for ultra-clean water.We worked with the GEAR Lab at MIT to compare new vs. used reverse osmosis elements. Our scan of a new reverse osmosis filter looks almost like a lithium-ion battery, with delicate but uniform layers surrounding a columnar core. Water has a pathway, impeded as it should be only by the membrane’s mesh pores. The filter worked 12 hours on, 12 hours off, for two months, then we scanned it again. Having purified a hard water supply high in mineral content, the filter now displays scars of its valiant efforts. Scaling deposits of minerals and organic matter visibly clog the layers, restricting water flow and reducing filtration efficiency.LifeStrawThe LifeStraw is a portable, personal water filter designed for outdoor adventures, travel in areas with unreliable water quality, and emergency preparedness. Unlike reverse osmosis, which relies on a semi-permeable membrane to remove dissolved solids, the LifeStraw uses hollow fiber membranes with microscopic pores to physically block contaminants like bacteria, parasites, and microplastics. This ensures clean drinking water on the go, without requiring electricity or extensive setup, making it ideal for hikers, campers, and those in disaster relief situations.A CT scan of a new LifeStraw reveals its uniform, open hollow fibers, which allow water to flow freely while trapping harmful particles along the way. Over time, and with frequent use, these fibers near the inlet begin to clog as debris accumulates, reducing both flow efficiency and the safety of the water that passes through. That makes regular cleaning a must for maintaining the performance of LifeStraw in challenging environments.Filtration for the FutureIndustrial CT offers a new level of transparency into the performance and lifespan of water filters. For consumers, it provides valuable insights into the unseen changes filters undergo, helping them make informed decisions about when to replace a filter to maintain the highest water quality. It removes the guesswork, letting us see the tangible effects of contaminants and wear over time.For manufacturers, CT scanning unlocks critical opportunities to refine designs and materials. By understanding exactly how and where blockages form, they can create filters that are not only more efficient but also longer-lasting and better suited to the diverse needs of their customers. Whether it’s tweaking carbon density or optimizing membrane layers, these improvements translate into more reliable products.Filters are more than just tools—they’re protectors of our health and safety. CT scanning goes beyond the surface, offering a glimpse into their often overlooked work and paving the way for smarter designs. With this technology, we’re not just looking at filters; we’re transforming how they serve us, ensuring better water quality today and clearing the way for tomorrow’s innovations.

Materials World

What’s Inside a Battery?

Most of us carry batteries around every day without thinking about what’s inside them. Phones, laptops, and cars all rely on their power. From the outside they seem simple; inside they’re made of carefully chosen materials that have to work together to provide the right amount of power. Battery basics The main pieces of a battery are the anode, the cathode, a separator, and an electrolyte. Cathode materials have shifted over the years. They used to be lithium cobalt oxide or lithium manganese oxide, though those are mostly phased out. Today you’ll see acronyms like LFP (lithium iron phosphate) and NMC (nickel, manganese, cobalt). Each mix has different strengths: some give higher energy density, others last longer, or are a bit more stable and safer. Anodes are usually graphite spread onto copper foil. The electrolyte is what lets lithium ions move between the anode and cathode. It is often a liquid solvent, which can be flammable; there are also versions that use a polymer instead. Those can improve safety and sometimes performance. Separators are thin polymers that keep the anode and cathode from touching. Solid-state batteries go further by using solid electrolytes, though they are still in development. Making a battery is not just stacking parts together. Powders like graphite or lithium compounds are mixed into a binder and coated onto thin foils. How evenly that coating spreads affects how it dries and how it compresses later. The tricky part is that every material behaves differently. You cannot simply swap one formulation for another and expect the process to work; each one needs its own set of parameters, which means testing, adjusting, and running trials until it works consistently. Competing priorities Every choice in battery design comes with trade-offs. Cost is always a factor; if a battery is too expensive, it will not make it to market. Safety is another non-negotiable. Failures can lead to recalls or worse. Beyond those, it depends on the application. Some batteries need the highest possible energy density, like those in electric cars. Others need long cycle life, like batteries for grid storage. Engineers weigh performance factors such as energy, lifespan, safety, and affordability against what the end product requires. Supply chain and recycling Batteries rely on critical minerals such as lithium, cobalt, nickel, and graphite; each is sourced from different parts of the world. That makes supply chains important. Tariffs, import sources, and political shifts all play a role in availability and cost. Recycling can help, and new processes are being developed, but it remains complicated. Each battery chemistry uses a different mix of metals, which makes separating them difficult. Recycling techniques depend on the physical and chemical properties of the powders and foils, so a process that works for one chemistry will not necessarily work for another. There is also the economic side. Recycling only makes sense if the materials are valuable enough to recover. Using less expensive materials can reduce dependence on scarce resources; it can also make recycling less worthwhile. Finding defects It only takes a small flaw inside a battery to cause an issue. Historically, anode overhang, where the anode extends too far past the cathode, has been a primary concern. Other defects include poor tab welds, wrinkles, or tears in electrodes. One of the main issues today is foreign particles. Tiny bits of metal can break off during welding or cutting, or fall in during assembly; those particles can trigger failures. [Embedded scan] To catch these problems, you need ways to look inside the sealed battery. CT scanning is one option, and it can detect very small particles, even down to a few microns. Ultrasound can also work, though with lower resolution. Destructive testing is another method, but it is slow and not practical for every battery that comes off the line. Balance From the outside, a battery looks simple. Inside, it is a complex mix of materials, processes, and trade-offs. Every decision, whether it is choosing LFP over NMC or tweaking how powders are coated, has ripple effects on performance, cost, safety, and recyclability. There is no perfect recipe; it is always about finding the right balance for the job at hand.

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Design to Reality Design to Reality

The Quality Gap The Quality Gap

Materials World Materials World

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From The Floor From The Floor

Recall Roundup Recall Roundup

Design to Reality

September 2025

Building for the Brain: Pioneering a Long-Term Neural Implant

Reviewed by Kurtis Nishimura

In this Article:

Connexus® is a brain-computer interface that restores speech by converting neural activity into real-time spoken language.
Designed for minimal heat generation, long-term biocompatibility, and a 10-year implant lifespan, meeting FDA Class III medical device standards.
Following a successful first-in-human trial, Paradromics is preparing an Early Feasibility Study (EFS) to evaluate long-term safety and performance.

When you’re building an implanted medical device for the brain, you can’t cut corners. Engineering for performance is a given when you’re designing for a living system. To ensure that there are no adverse effects, an active implantable device cannot dissipate excessive heat, or there could be a risk to the surrounding tissue. Every decision, from materials, to power draw, and even packaging, is shaped by the need to do no harm. Designing a medical device is a totally different world from consumer electronics.

Stakes of the system

At Paradromics, we’re building a brain-computer interface (BCI) to restore speech for people with severe communication disorders: conditions like ALS or spinal cord injury that disrupts the connection between intention and expression. Our first product, Connexus^® BCI, records directly from the brain’s speech centers and synthesizes intended speech in real time.

The Connexus® brain-computer interface (BCI) by Paradromics.

Our goal is a device that never has to be replaced. That means every material choice and assembly step matters.

My focus as an electrical engineer is on the Cortical Module itself. That’s the component that sits on the surface of the brain, and it’s also the point where the technical demands are highest. The Cortical Module must be reliable, power-efficient, and manufacturable at scale. And it has to last a long time; because we are not interested in devices that require users to have brain surgery to replace their brain implant every two years as with some technologies being explored by others. Our goal is a device that never has to be replaced. That means every material choice and assembly step matters.

People often compare implants like ours to wearable electronics, such as a smartwatch or continuous glucose monitor, as they share some similar goals: small size, clean data, minimal intrusion. But once you’re under the skin, everything changes. Now you’re dealing with strict FDA regulations, biocompatibility constraints, and failure modes with the highest possible stakes.

A neurosurgeon places the Connexus® BCI system under the skin: cortical module, internal transceiver, and extension lead. The microelectrodes of the cortical module extend just below the brain’s surface to gather rich signals from individual neurons in the motor cortex.

Incompressible timelines

Some timelines are just incompressible, and you have to come to terms with that. You can move fast in design, but once the project moves into manufacturing and validation, your pace becomes capped to that of regulation and biology. I wish someone had told me going into this field, that even with unlimited resources and engineering expertise, there are parts of the process you simply can’t speed up.

Regulatory requirements shape design from day one. Connexus BCI is classified as a Class III medical device, the same category as a pacemaker. Implanted medical devices are typically limited to known biocompatible materials, and to support a minimum of a 10 year implant life that means materials like titanium, platinum, and gold. You can try to get new materials approved, but it’s a much longer road. And when you’re already working on a novel device, it’s wiser to avoid adding extra unknowns.

Building the plane while flying it

There’s no off-the-shelf playbook for what we’re doing. Our system isn’t life-supporting like a pacemaker, but it is life-enhancing. We work closely with the FDA to define safety and benefit to the patient for a device that doesn’t quite fit their existing categories. We’re being evaluated, while also helping define the rules.

You have to keep moving forward, even while you’re clearing the path beneath your feet.

The metaphor we use internally is “building the plane while flying it.” It may sound chaotic, but it’s just the reality of working in a space this new. You have to keep moving forward, even while you’re clearing the path beneath your feet.

Testing for the future

That pressure to get it right shows up most in testing. Our devices go through a long chain of inspection, step by step. Some processes require equipment so specialized there’s no commercial equivalent, meaning we have to do it ourselves. That’s why we use Lumafield's industrial CT scanner to evaluate process outcomes and observe internal structures that can’t be seen any other way. It’s one of the few tools that can keep up with the level of precision we need.

CT scans of Paradromics’ Connexus® system show a precision-manufactured electrode array with stems thinner than a human hair and tips smaller than a red blood cell and an implantable flexible connector that links the brain and chest implants.

In addition to testing in a large animal model, we also run accelerated aging tests, environmental stress simulations, and strenuous mechanical validation to make sure our devices can survive in the body for years. This includes checking for things like thermal performance, electrode durability, and even the consistency of raw materials from one vendor to another.

Milestones that matter

This work isn’t theoretical. Earlier this year, we completed our first human implantation in a patient undergoing unrelated brain surgery. The successful recording and data collection demonstration confirmed that our device performs well in the real world. We saw the kind of neural activity we expected and it validated years of animal studies and lab work.

Dr. Matthew Willsey working in the operating room. Courtesy of Paradromics and the University of Michigan.

That milestone puts us on the path toward an Early Feasibility Study (EFS), a longer-term clinical investigation, where the device stays in place and is used regularly by a small number of participants. It’s the next big step toward FDA approval.

Designed to stay

I joined Paradromics right out of college in 2022, drawn to the cutting-edge intersection of engineering and neuroscience. It’s still a young field, and there’s so much left to figure out. But if we’re going to make a real difference for patients, we have to meet the body where it is. That means durability, reliability, and empathy for the people at the center of it all.

This Cortical Module should feel less like a medical device and more like a part of someone’s life. If we can get there, we’ll have done our job.

Citations

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Alec Mehra

AUTHOR

Electrical Engineer at Paradromics

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