27 February 2026

The Surprising Flaws in 18650 Lithium-Ion Batteries

The standard 18650 lithium-ion battery can be found in almost every modern household, whether in rechargeable battery packs, flashlights, or even replica lightsaber hilts. Alex Hao and Andreas Bastian of Lumafield visit the cave to share the results of CT scanning over a thousand lithium-ion batteries, and the hidden risks they uncovered in battery manufacturing defects and quality control inconsistencies. 




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

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