Defect Management System (DMS): Smarter QC Across All Inspection

See the system live at our booth all day Optical Measurement Module (OMM): In-Line µm Electrode Inspection for Predictive Quality in Battery Manufacturing As battery manufacturers face increasing pressure to reduce costs while maintaining high quality, traditional inspection methods are no longer enough. Enter the Optical Measurement Module (OMM) —PDF Solutions’ AI-powered, high-resolution inspection system designed to transform battery production from reactive to predictive . OMM leverages advanced optical imaging and machine learning to detect surface texture anomalies, impurities, and process drift in real time—without requiring prior process knowledge. With a resolution of 1-3 µm, OMM captures microstructures and surface defects that conventional systems miss, enabling manufacturers to catch issues early, reduce scrap, and improve yield. Unlike traditional inspection tools that are reactive and subjective, OMM delivers rich, objective data insights that correlate directly with yield and equipment health. It identifies early signs of equipment wear, such as calender roll degradation or slurry clumping, allowing for predictive maintenance and tighter process control. Key Capabilities: Detects organic/inorganic impurities and metallic particles as small as 15 µm Monitors surface porosity, grain size, and texture oscillations Enables real-time, inline inspection during electrode production Correlates surface data with yield to identify root causes of variability Reduces downtime, rework, and over-maintenance Proven Use Cases: Impurity Detection in NMC : OMM identified impurities missed by conventional systems, reducing scrap and improving material quality. Cathode Process Optimization : A major LFP cell manufacturer used OMM to uncover yield-impacting surface texture changes, leading to actionable process limits and improved consistency. Why OMM? Battery manufacturing is entering a new era—one where AI, automation, and data-driven decisions are essential. OMM gives manufacturers the edge to stay competitive by enabling smarter, faster, and more cost-effective production. Backed by PDF Solutions With over 30 years of experience in semiconductor analytics, PDF Solutions brings deep expertise in complex manufacturing environments. Our technologies manage over 40,000 tools globally and are trusted by 18 of the top 20 semiconductor companies. Now, we’re bringing that same innovation to batteries. Learn More Watch our recent webinar to see OMM in action and hear how leading manufacturers are using it to drive real ROI: 👉 For more information, visit www.pdf.com/battery or contact sales@pdf.com . | Improved QC with integrated Defect Management System (DMS) In battery manufacturing, not all defects are created equal—and not all inspection tools speak the same language. PDF Solutions’ Defect Management System (DMS) solves this by providing a centralized, inspection-agnostic platform that unifies defect data across all vision systems and production equipment. DMS enables manufacturers to accurately assess which defects truly impact product quality by correlating defect types, locations, and frequencies with downstream cell performance. Whether it’s surface contamination that increases self-discharge or burrs that compromise insulation, DMS helps you distinguish between critical and non-critical defects—reducing false rejects and escapes. Key capabilities include: Centralized Defect Aggregation : Integrates data from all inspection tools and production stages. Defect Genealogy & Traceability : Tracks defects from electrode roll to stacked cell, including substrate size changes. Defect Libraries : Categorize and rank defects based on their impact on yield and performance. Tool Health Monitoring : Identifies malfunctioning tools through pattern recognition and defect clustering. Data-Driven QC Optimization : Adjust quality thresholds based on real-world impact, not assumptions. DMS empowers quality teams to move from reactive inspection to proactive quality control. By understanding which defects matter most, manufacturers can fine-tune processes, reduce unnecessary scrap, and improve overall yield.