Scientists at the University of Surrey have built tiny new tools that let them see what happens inside a battery while it’s running—something that has never been possible before.
This breakthrough could lead to safer, longer-lasting, and faster-charging batteries for electric vehicles, renewable energy systems, and everyday devices.
Until now, batteries have been like sealed “black boxes.”
Researchers could measure how much energy went in and out, but they couldn’t directly see what was happening inside.
With these new microdevices, Surrey scientists can now watch the inner workings of a battery in real time.
They can track how chemical reactions unfold, how materials expand and contract, and even how gases form when a battery is charging or discharging.
The new tools can reveal tiny structural changes—known as nanoscale surface morphology—that occur on the battery’s surface during operation.
They also allow researchers to analyze the interface where key chemical reactions happen and measure atomic-level changes in mass.
This information helps explain why batteries lose power over time, overheat, or sometimes fail completely.
The research team, led by Dr. Kai Yang from Surrey’s Advanced Technology Institute, has also created a range of “mini-labs-on-a-chip.”
These small testing systems make it possible to quickly experiment with new materials and designs without building full-sized batteries.
The goal is to speed up innovation in battery technology, helping engineers design cells that are more efficient, stable, and environmentally friendly.
“Batteries power everything from smartphones to electric vehicles, but what happens at the tiny interfaces inside them has always been a mystery,” Dr. Yang explained.
“These hidden zones control how well a battery performs, how long it lasts, and how safe it is. Our work aims to reveal and control these invisible processes.”
Professor Ravi Silva, Director of the Advanced Technology Institute, said the technology represents a major leap forward. “For the first time, we can actually peek inside batteries and adjust their performance in real time,” he said. “It’s a game-changer for clean energy research and perfectly fits our mission to support the global transition to net-zero emissions.”
The Surrey team is now partnering with industry groups, including Merrow Scientific, LinkZill, and R3V Tech, to expand the use of their devices beyond the lab. Their innovations could also benefit green chemical production and environmental monitoring, where precise, real-time testing tools are crucial.
If successful, this breakthrough could mark the start of a new era in battery science—one where we can not only understand but also design the inner life of batteries for a cleaner, safer, and more sustainable future.
