Body Camera Battery: Why Quality Assurance Determines Safety

When first responders put on their body camera in the morning, they probably don’t think about battery technology. They rely on the device working – for hours, in any weather, in stressful situations. The small camera is supposed to document operations and serve as evidence. But this very reliability is the result of complex technical processes that begin long before the first deployment.

In this article, we explain why a battery can become problematic, what warning signs indicate wear, and how risks can be avoided through consistent quality assurance.

Due to Battery Problems: Body Cameras Taken Out of Service

Recent incidents have brought the issue into focus: In several German states, devices have been recalled due to battery problems. Particularly affected were the police in North Rhine-Westphalia and Baden-Württemberg. Recently, body cameras also had to be taken out of circulation in Saxony-Anhalt – similar problems to those in other regions.

A visible warning sign: In several cases, the cells of the affected batteries have swollen. This creates a gap between the camera and the mounting plate. This small gap indicates that the battery is compromised or defective and needs to be replaced gradually.

The problems with body cameras are not isolated cases. The same technology also regularly makes headlines with smartphones, e-bikes, and laptops. The causes are often identical: production defects, material fatigue, or thermal wear.

How Does the Battery in a Body Camera Work?

Most body cameras use lithium polymer or lithium-ion batteries. These types offer high energy density: they store a lot of energy at low weight – ideal for a device worn on the body all day.

The operating principle: During discharge, lithium ions travel from the negative electrode (anode) through an electrolyte to the positive electrode (cathode). During charging, the process reverses. Between the electrodes lies an extremely thin separating layer, the so-called separator. It prevents the electrodes from touching – because that would be a short circuit.

This is exactly where the risk lies: The high energy density that makes the battery so powerful becomes a hazard when the separator is damaged through wear or defects.

Why Do Batteries Swell?

A defective or problematic battery typically goes through several phases:

Phase 1: Internal Damage Through Wear

Production defects, mechanical damage, or natural wear of the batteries can cause the separator to become damaged. Dendrites (metallic deposits) can also grow. These defects are usually not visible from the outside – the cell does not yet appear abnormal.

Phase 2: Affected Batteries Swell

Chemical reactions inside generate gases. Affected batteries often swell – a clear warning sign. With body cameras, this manifests as a small gap forming between the camera and mounting plate. The device no longer fits properly in its holder.

Phase 3: Thermal Runaway

If an internal short circuit occurs in such cases, the cell heats up rapidly. Above a critical temperature, a chain reaction begins. The battery can melt, catch fire, or in extreme cases explode. Damage images show how dangerous this process can become.

Similar Problems: Not Only with Body Cameras

These incidents are part of a long list:

• ✓ Samsung Galaxy Note 7 (2016): Due to battery problems, Samsung had to recall millions of devices. The damage: several billion euros and massive reputational loss.
• ✓ E-bike batteries: Defective pedelec batteries repeatedly cause garage fires. Fire departments warn against charging e-bikes unattended.
• ✓ Laptops and tablets: HP, Dell, Apple – virtually every major manufacturer has had recalls due to problematic batteries.
• ✓ Body cameras in Germany: Police in North Rhine-Westphalia, Baden-Württemberg, and Saxony-Anhalt reported similar problems with swollen cells.

What Should Procurement Officers Look for in Body Cameras?

For government agencies and companies procuring devices, a closer look is worthwhile. The following questions help avoid problems:

1. What Testing Processes Does the Battery Undergo?

A simple visual inspection is not sufficient to detect internal defects or beginning wear. Reputable manufacturers rely on multi-stage quality controls: at the supplier, at goods receipt, and before installation. The more testing stations, the lower the risk.

2. Is There Active Battery Management?

Modern body cameras should have integrated electronics that continuously monitor charging current, voltage, and temperature. A good battery management system (BMS) detects abnormal values early and can interrupt the charging process.

3. How Is Wear Detected and Documented?

4. Is the Body Camera Suitable for Continuous Use?

Not every small camera is suitable for professional use. Make sure the device is designed for continuous operation and whether the recordings are admissible as evidence in court.

Detecting Wear: From X-Ray to Computed Tomography

The most reliable method for detecting internal defects and wear is non-destructive testing. The battery is examined without opening or damaging it.

Provides two-dimensional images of the interior. Gross defects such as foreign particles or severely deformed electrodes become visible. However, this method is often not sufficient for detailed analysis.

The gold standard method. By combining many X-ray images, a three-dimensional image is created. Even the finest cracks, dendrite growth, or irregularities become visible – before the cell becomes compromised or defective. Damage images from CT analysis show precisely where problems originate.

Industrial CT systems are excellently suited for quality assurance. In Germany, Microvista GmbH – a sister company of NetCo Professional Services – offers such testing as a service.

Case Study: How NetCo Prevents Problems

As one of the few German manufacturers in the professional segment, NetCo has developed a multi-stage safety concept:

• ✓ Before installation: Every battery passes through three testing stations – at the cell manufacturer, at goods receipt in Blankenburg, and again before assembly. If necessary, random samples can be CT-scanned to detect damage images early.
• ✓ During operation: An integrated battery management system continuously monitors the cell. Charging current and temperature are documented, abnormal values detected before problems arise.
• ✓ After delivery: Under refurbishing agreements, devices are regularly serviced. Batteries showing wear are gradually replaced. This ensures that the body camera works reliably even after years of continuous use and remains suitable as evidence.

The result: Among long-standing customers – including police authorities and transport companies throughout Germany – no safety-relevant incidents have occurred.

Conclusion: Similar Problems Are Preventable

The incidents at the police in North Rhine-Westphalia, Baden-Württemberg, and Saxony-Anhalt show: This topic deserves more attention. Devices had to be recalled due to battery problems – in several cases among other things due to abnormal or swollen batteries – but similar problems can be prevented through consistent quality assurance.

For procurement officers, this means: Don’t just look at features and price, but also ask how the manufacturer handles wear and quality control. Check whether the body camera is suitable for continuous use and whether recordings can serve as evidence. Because ultimately, it’s about the trust of first responders in their equipment – and their safety.

Would you like to learn more about the safety of the NetCo Body-Cam Pro?

• ✓ View technical specifications
• ✓ Request a consultation
• ✓ CT inspection by Microvista