The Illusion of Cleanliness: Inside Battery Factories

University of Maryland mechanical engineer Michael Pecht, a veteran auditor of battery production facilities, describes the contrast starkly. Some factories operate with “semiconductor-type cleanliness,” resembling sterile hospital environments. However, Pecht’s inspections have also revealed alarming lapses in hygiene and quality control – employees smoking near production lines, watering plants in sensitive areas, and a general disregard for contamination prevention. These seemingly minor infractions can compromise battery performance and, critically, safety.

Beyond Sloppy Practices: The Counterfeit Crisis

These lapses in manufacturing standards are concerning, but they represent only the beginning of the problem. Pecht estimates that dozens of factories he’s audited have produced poorly assembled cells lacking essential safety features, and even outright counterfeit batteries. These fakes, often mimicking well-known brands like LG, Panasonic, or Samsung, are appearing in a wide range of devices – from e-bikes and scooters to vape pens and power tools. The consequences can be devastating, with reports of fires and explosions resulting in serious injuries and fatalities.

New York City’s Response: A Ban and a Battery Swap Initiative

The escalating crisis reached a critical point in New York City, where a rash of fires attributed to faulty e-bike batteries prompted decisive action. In 2024, the city banned the sale of uncertified batteries, aiming to remove dangerous products from circulation. Furthermore, the city is investing in a network of e-bike battery-swapping stations, offering delivery riders a safer alternative to charging potentially hazardous batteries at home.

The Severity of Fakes: An Order of Magnitude Worse

Experts believe the dangers posed by counterfeit batteries are significantly underestimated. “It is probably an order of magnitude worse with these counterfeits,” Pecht asserts, highlighting the critical difference between certified batteries, which undergo rigorous testing, and the often-shoddy construction of fakes.

How Counterfeit Batteries Are Made

Counterfeiters employ several tactics. Some simply relabel old or scrap batteries as new, capitalizing on the difficulty in visually distinguishing them from legitimate products. Others rebadge genuine batteries with inflated capacity claims, misleading consumers about their performance. However, the most prevalent – and dangerous – counterfeits are entirely homemade, assembled in makeshift facilities with minimal quality control.

The Science of Safety: What Legitimate Batteries Do Right

Certified lithium-ion batteries incorporate multiple safety mechanisms to prevent catastrophic failures. Judy Jeevarajan, vice president and executive director of the Electrochemical Safety Research Institute at Underwriters Laboratories, led a study comparing genuine and counterfeit batteries. The research revealed stark differences in construction. Legitimate batteries feature thick plastic insulators, robust tape securing the internal “jelly roll,” and critical safety features like Positive Temperature Coefficient (PTC) – which increases resistance as temperature rises – and Current Interrupt Devices (CID), which disconnect the circuit during overpressure events. Counterfeit batteries routinely lack these vital components.

Jeevarajan’s team found that while counterfeiters meticulously replicate external labeling, they consistently skimp on internal safety features. The iconic 18650 lithium-ion cylinder, when genuine, demonstrates superior insulation and a functioning CID, features often absent in counterfeit versions.

Identifying a Fake: A Difficult Task

Distinguishing a counterfeit battery from a genuine one can be incredibly challenging, even for experienced professionals. “One cannot tell from visually inspecting it,” Jeevarajan explains. While dismantling the battery reveals the lack of safety features, this isn’t a practical option for most consumers. Companies can employ comparative testing, using known legitimate batteries as a benchmark. More advanced techniques, like CT scans, can reveal internal construction flaws, but these are beyond the reach of the average buyer.

What types of batteries are most at risk? Pecht advises focusing on cylindrical batteries found in lower-cost devices. Smartphones and electric vehicles, subject to stringent quality control, are less likely to contain counterfeits. Jeevarajan adds, “They are mostly found as energy and power sources for portable applications that can vary from your cameras, camcorders, cellphones, power banks, power tools, e-bikes and e-scooters.”

Do you think current regulations adequately address the issue of counterfeit batteries, or should manufacturers bear more responsibility for supply chain security? And how can consumers better protect themselves from these hidden dangers?

The core issue, Pecht argues, isn’t consumer behavior – improper charging or storage – but the presence of substandard cells in the supply chain. “They want to blame the user… But in my view, it’s the cells themselves” that are the problem.

Frequently Asked Questions About Counterfeit Lithium-Ion Batteries