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Our experts have conducted root cause failure analyses of cells and battery packs used in laptops, power tools, HEV cells, cell phones, and other consumer electronics. This work was done on several battery chemistries (Li-ion, Li-polymer, Lead acid, Nickel metal hydride, and Alkaline) and designs (cylindrical, prismatic, pouch, and coin cells). During the late 1990’s and early 2000’s, our experts worked with major laptop and Li-ion cell manufacturers to find the root cause of these failures. Various issues were found such as improper winding of the jelly roll, uneven coatings, unbalanced effective electrode mass, and foreign contaminant particles. This study found that two of the major causes of cell failure were the presence of contaminants and spot welding of the current collector.