CALCE Research Featured in Batteries Editor's Choice Articles

CALCE lithium-ion battery safety research

A research paper by CALCE researchers Sahithi Maddipatla, Lingxi Kong, and Michael G. Pecht has been recognized as an Editor’s Choice Article by Batteries, an international journal published by MDPI. Selected among just 10 Editor’s Choice articles published in 2024 and 2025, the paper represents CALCE’s ongoing contributions to advancing battery research and improving our understanding of battery performance and safety.

The featured paper, "Safety Analysis of Lithium-Ion Cylindrical Batteries Using Design and Process Failure Mode and Effect Analysis" was published in Batteries in 2024. As cylindrical lithium-ion batteries become increasingly common in consumer electronics, electric vehicles, and energy storage applications, ensuring their safety requires identifying potential failure mechanisms before they develop into serious events such as thermal runaway, fire, or explosion. This study addresses this need by evaluating safety risks arising from both battery design and manufacturing processes.

Integrated safety analysis of cylindrical lithium-ion batteries

The research applies Design Failure Mode and Effect Analysis (DFMEA) and Process Failure Mode and Effect Analysis (PFMEA) to systematically trace potential failure modes to their causes and effects. The analysis identifies internal short circuits, localized heating, abnormal gas generation, and malfunction of safety devices as key mechanisms that can lead to thermal runaway. It further traces these mechanisms to specific design and manufacturing factors, including separator properties, electrode and electrolyte characteristics, moisture, coating and calendaring conditions, welding, electrolyte wetting, and cap assembly.

The integrated analysis provides a direct link between potential failure causes and actionable controls. The study shows how design parameters can be incorporated into failure-mechanism models, while manufacturing-related causes can be addressed through targeted in-process quality checks. This approach can help identify high-risk conditions earlier, support root-cause analysis, and guide battery design and manufacturing decisions toward improved safety.The selection of this work as an Editor’s Choice article recognizes its contribution to understanding and addressing battery safety risks.

The recognition also underscores CALCE’s continued contributions to battery safety and reliability research. This work complements CALCE’s broader research on battery failure mechanisms, reliability assessment, and life-cycle engineering. Related CALCE research on lithium-ion batteries includes studies of electrolyte leakage, core collapse, battery degradation, thermal behavior, and battery safety.

Related research papers can be found on CALCE’s battery publications page.

For information about CALCE’s broader work in battery safety research, contact Prof. Michael Pecht.

For additional information about this article and related work, contact Sahithi Maddipatla.

Published September 1, 2026