On-Scanner 3D Inspection for EV Battery Development

Why KE-TEC Choose FreeScan Omni

When EV battery systems are pushed to their limits, even the smallest deformations can matter. Based in Germany, KE-TEC GmbH supports the development of lithium-ion EV batteries by turning physical test results into reliable, simulation-ready data, helping automotive OEMs, suppliers, and battery manufacturers make confident engineering decisions.

The Challenge: Measuring Complex Deformations Under Real-World Constraints

For KE-TEC, battery testing does not end with a mechanical stress test. After scenarios such as crush tests, engineers must accurately capture how a battery housing has deformed, as this data feeds directly into simulation models used for safety validation and design decisions.

Once a housing is distorted, however, its geometry becomes difficult to measure using conventional methods. At the same time, KE-TEC’s automotive customers expect results that are both accurate and delivered quickly. Many commonly used 3D scanning systems rely on wired connections and external workstations, limiting the flexibility needed for KE-TEC’s agile, project-driven workflow.

The Solution: A Standalone Inspection-Ready Metrology 3D Scanner

Key Advantages of FreeScan Omni:
- Standalone & wireless metrology 3D scanner for flexible inspection
- Fast setup and efficient scanning in real-world test environments
- On-scanner scan-to-inspect with direct on-device CAD comparison
- Consistent volumetric accuracy for large EV battery housings via VPG

To overcome the challenge, KE-TEC integrated SHINING 3D Metrology’s FreeScan Omni into its battery testing workflow. As a standalone inspection-ready metrology 3D scanner, FreeScan Omni combines certified accuracy, wireless operation, onboard data processing, and inspection capabilities in a single device.

After mechanical stress tests, engineers can move directly to the battery housing, perform the scan, and evaluate deviations on the spot—without external workstations or fixed scanning setups. With an integrated PTB-certified SHINING3D Inspect module, scan data can be aligned with CAD models immediately, allowing deviations and deformation patterns to be visualized and assessed directly on the device. This shortens feedback loops and enables faster, data-driven decisions during development and validation.

EV battery housings are typically large components—often exceeding one meter in size—making consistent volumetric accuracy essential when capturing deformation across the entire structure. For such large-scale objects, FreeScan Omni leverages patented Video Photogrammetry (VPG) to ensure reliable volumetric accuracy of 0.02 + 0.015 mm/m, meeting automotive inspection requirements with minimal setup.

More Than a Scanner: A Long-Term Partner

Beyond the technology itself, KE-TEC values SHINING 3D’s ongoing innovation and support. Regular product updates and close collaboration with SHINING 3D’s engineering team have strengthened KE-TEC’s confidence in the long-term value of FreeScan Omni.

“We chose SHINING 3D because of their impressive pace of innovation. FreeScan Omni is the first handheld scanner we’ve seen that can be fully operated without a PC while still delivering performance comparable to a workstation-connected device. For a company like ours, being agile is essential. The SHINING 3D team has been extremely helpful, and the complete package fits perfectly into our workflow.”

— Antonio Weixler, Project Engineer at KE-TEC GmbH

By adopting FreeScan Omni, KE-TEC GmbH has bridged the gap between physical testing and digital simulation. The scanner’s portable, standalone, and wireless design enables faster feedback from test to analysis, helping KE-TEC accelerate battery development and support automotive customers with greater confidence.