Good Practice #1 | Turning failure insight into a shared “Sense & Repair” compass

Early on, our labs were seeing similar degradation patterns from different angles. The evidence was strong but scattered across notebooks and post mortems. We needed one shared compass to turn that learning into the few signals that would help the battery help itself.

What we did

We distilled core findings into a concise and co-created a Sense & Repair design note that everyone can build on. In plain language it sets out:

• What we must sense: early thermal, mechanical, and gas indicators as practical flags of oncoming trouble.
• Where to sense: near critical interfaces so hotspots, cracking, swelling and early gas formation are detected without disturbing the stack.
• How to react: start simple – localised, controlled interventions orchestrated by the BMS – then iterate.

Results at a glance

A single 2–3 page “Sense & Repair” brief now referenced in build sheets and test plans; faster handoffs between teams, fewer “nice-to-have” experiments; more “need to prove” ones which improved cross team communication and confidence in early testing cycles.

Next steps

Refresh the note after each pouch cell sprint so new evidence immediately updates the compass.