Abstract
The reliability of electric vehicle (EV) batteries requires detecting surface defects but also precisely locating them on the physical module for automated inspection, repair, and process optimisation. Conventional 2D computer vision methods, though accurate in image-space, do not provide traceable, real-world defect coordinates on complex or curved battery surfaces, limiting utility for digital twins, root cause analysis, and automated quality control. This work proposes a hybrid inspection pipeline that produces millimetre-level three-dimensional (3D) defect maps for EV battery modules. The approach integrates (i) calibrated dual-view multi-view geometry to project defect points onto the CAD geometry and triangulate them where dual-view coverage is available, (ii) single-image neural 3D shape inference calibrated to the module geometry to complement regions with limited multi-view coverage, and (iii) generative, physically informed augmentation of rare or complex defect types. Defects are first detected in 2D images using a convolutional neural network (CNN), then projected onto a dense 3D CAD model of each module, complemented by a single-image depth prediction in regions with limited dual-view coverage, yielding true as-built localisation on the battery's surface. GenAI methods are employed to expand the dataset with synthetic defect variations. Synthetic, physically informed defect examples are incorporated during training to mitigate the scarcity of rare defect types. Evaluation on a pilot industrial dataset, with a physically measured reference subset, demonstrates that the hybrid 3D approach achieves millimetre-scale localisation accuracy and outperforms a per-view CNN baseline in both segmentation and 3D continuity.