The manufacturing industry is at a critical inflection point. As electric vehicle adoption accelerates globally, battery production quality has never been more crucial. At last week’s Automate 2025 show in Detroit, our team had the privilege of demonstrating a breakthrough technology that addresses one of the most persistent challenges in battery manufacturing: comprehensive internal inspection of 4680 battery cells.
A Dynamic Demonstration That Captured Attention
In partnership with lighting specialists CCS, VisionLabHub’s booth featured a live demonstration of our COOLENS® 360° Inner Wall Inspection Lenses in action. The setup allowed visitors to witness real-time inspection of 4680 battery cells—the same form factor used in many leading electric vehicles today.
What made this demonstration particularly compelling was its dynamic nature. Unlike static displays that show only capabilities under ideal conditions, our system performed continuous inspections while the battery cells moved through the inspection station. This real-world simulation highlighted the technology’s robustness in production environments where speed and reliability are paramount.
The Technology Behind the Innovation
At the heart of our demonstration was the PRHI230-82 inspection lens, part of our COOLENS® series specifically designed for challenging internal inspection applications. These specialized lenses enable simultaneous imaging of both the inner walls and bottom surfaces of cylindrical objects—a capability that conventional inspection systems simply cannot match.
The technical specifications tell part of the story:
- Working distance range: 5-65mm (significantly more flexible than competing solutions)
- Compact design: Minimum outer diameter of just 12mm allows inspection of narrow openings
- Superior image quality: Crisp, clear images from edge to edge with minimal distortion
- Uniform illumination: Consistent lighting throughout the entire inspection area
But seeing was truly believing at Automate 2025. Visitors could directly compare our imaging results with those from other inspection systems, and the difference was immediately apparent. Where competing solutions showed blurring, distortion, or poor illumination at the edges, our system delivered consistent clarity throughout the entire field of view.
Why 360° Internal Inspection Matters for Battery Production
The 4680 battery cell format (46mm diameter, 80mm height) has become increasingly important in the EV industry due to its improved energy density and thermal performance. However, manufacturing these cells at scale while maintaining quality presents significant challenges.
Internal defects in battery cells can lead to:
- Reduced capacity and performance
- Shortened lifespan
- Potential safety issues in extreme cases
Traditional inspection methods often fail to detect subtle issues like small burrs, inconsistent welds, or contamination on the inner surfaces. These seemingly minor imperfections can develop into serious problems once the battery is in use, potentially leading to warranty claims or recalls.
Our 360° inspection technology addresses these challenges by providing complete visibility of internal surfaces during the manufacturing process. The ability to identify and reject defective cells before they’re integrated into battery packs represents significant value for manufacturers in both quality assurance and cost reduction.
Industry Response and Applications Beyond Batteries
The response from industry professionals at Automate 2025 was overwhelmingly positive. Beyond battery manufacturers, we received inquiries from companies in several other sectors:
Medical Device Manufacturing
Representatives from medical device companies expressed interest in applying the technology to inspect internal components of precision instruments, where surface integrity is critical for both function and sterility.
Aerospace Components
The aerospace industry, with its extraordinarily high quality standards, saw potential applications in inspecting internal surfaces of hydraulic components and critical fastener holes.
Automotive Manufacturing Beyond Batteries
Traditional automotive manufacturers recognized applications for inspecting engine blocks, transmission components, and other parts with complex internal geometries.
Food and Beverage Packaging
Even food and beverage manufacturers showed interest in applying the technology for ensuring container cleanliness and integrity.
The Power of Partnership: VisionLabHub and CCS
Our successful demonstration at Automate 2025 wouldn’t have been possible without our collaborative partnership with CCS, industry leaders in machine vision lighting. The integration of CCS’s precision lighting solutions with our optical technology created a complete inspection system greater than the sum of its parts.
This collaboration exemplifies our approach to solving complex industrial challenges—by combining specialized expertise across disciplines, we deliver integrated solutions rather than just components.
Looking Beyond the Show: The Future of Inspection Technology
As manufacturing continues to advance toward Industry 4.0 and beyond, inspection technologies like our 360° internal imaging systems will play an increasingly critical role. The ability to detect defects early in the production process not only improves quality but also generates valuable data that can be used to optimize manufacturing processes.
The next evolution of our technology, already in development, will incorporate advanced AI capabilities to automatically identify and categorize defects, further reducing the need for human intervention in the inspection process. This integration of optical excellence with machine learning represents the future direction of quality assurance in manufacturing.
Experience the Difference for Yourself
While Automate 2025 has concluded, the conversation about advanced inspection technology continues. We invite manufacturing professionals facing challenging inspection requirements to connect with our team for a personalized demonstration of our 360° inspection capabilities.
Whether you’re producing battery cells, medical devices, or precision mechanical components, the ability to comprehensively inspect internal surfaces can transform your quality assurance process. Our engineering team specializes in adapting our core technology to specific application requirements, ensuring you get not just a product but a complete solution.
Visit our product page for the PRHI230-82 COOLENS® 360° Inner Wall Inspection Lenses to learn more about specifications and capabilities, or contact us directly to discuss your specific inspection challenges.
Conclusion: Quality Inspection as a Competitive Advantage
As manufacturing processes become increasingly automated and products more complex, the importance of sophisticated inspection technologies only grows. Our successful demonstration at Automate 2025 confirmed what we’ve long believed: companies that invest in superior inspection capabilities gain a significant competitive advantage through improved quality, reduced waste, and enhanced process control.
The enthusiastic response from visitors across multiple industries validates our continued investment in pushing the boundaries of what’s possible in optical inspection. We look forward to continuing the conversations started at Automate 2025 and helping more manufacturers achieve their quality assurance goals with our advanced inspection solutions.
Did you attend Automate 2025? We’d love to hear your thoughts on the future of inspection technology in manufacturing. Connect with us on LinkedIn or contact our team directly to continue the conversation.
