Battery Laser Welding for Battery Pack Manufacturing
Laser welding is one of the most promising joining technologies for EV batteries and energy storage systems. It provides the speed and precision needed to make the thousands of welds that connect tabs and busbars in battery packs, modules, and cells.
All types of battery cells can be laser welded, including cylindrical cells, prismatic cells, and pouch cells. Laser welding is being implemented for a wide range of electric battery applications:
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The Benefits of Laser Welding Technology
Meet High-Speed
Production Requirements
With more than 6kW of laser power, the welding speed can be scaled to meet short cycle time requirements.
Lasers also require minimal maintenance, so they are ideal for production line automation.
Minimize the
Heat Affected Zone
Laser welding can be optimized for minimal heat input. As a result, batteries do not suffer from excessive heating and maintain better mechanical properties.
Join
Dissimilar Metals
Lasers can weld dissimilar materials with varying fusion temperatures without the need for filler material. Examples include steel-copper, steel-aluminum, aluminum-copper, and steel-nickel.
Adapt Quickly to
Production Variations
Laser parameters can be updated automatically for different needs. This is ideal if you are working with multiple module and pack designs involving various cell types and busbar thicknesses.
The welding process can also be updated on the fly for different thicknesses.
Customize
Welding Patterns
Because laser welding is a non-contact technology performed remotely, welding patterns can be customized and optimized for each application. This guarantees strong and reliable bonds regardless of the welding area’s size, shape, or location.
Improve
Electrical Conductivity
Metals joined by laser welding have an excellent electrical conductivity and better heat management at the welded joints (due to minimal resistance).
Laser Machines for Battery Manufacturing
Laserax provides turnkey solutions powered by high-power fiber systems. Our systems are specifically made for battery applications and offer the flexibility needed to take you from the design stage to full-scale production.
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Battery Laser Welding Machine
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Battery Laser Welding Workstation
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Battery Laser Cleaning Machine
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Expert Presentation of the Battery Laser Welding Machine
See the laser welding machine in action and discover its key features with this expert overview.
- Laser process with parameters such as weld shape and laser power
- Weld quality results including shear strength, electrical resistance, penetration depth, and aging
- Welding equipment including remote laser head, dynamic clamping system, vision cameras, laser source, gantry system, fume extraction system, and tool cleaning system
- HMI software for laser weld monitoring feedback and manual machine control
About the Expert
Marc-Antoine is Application Specialist at Laserax and Mechanical Engineer by training. On a daily basis, he discusses with clients to analyze their needs and present them with adapted laser solutions.
Laser Welding Services for Battery Manufacturing
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Laser Welding Process DevelopmentEach battery application requires a custom laser welding process adapted to the combination of materials, thicknesses, and cell dimensions. We develop the process for your requirements and perform a range of tests to validate weld quality, including electrical resistance, mechanical resistance, depth of penetration, aging, and a cross section SEM analysis to identify defects. |
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Laser Welding ServiceWe offer a laser welding service to weld complete battery packs. This is ideal if you need to start welding while are waiting for a machine order, if you need a batch of parts welded for prototyping or preproduction, or if you need to validate laser welding in your manufacturing process. |
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Laser Welding Machine RentalBefore you invest in a machine for full-scale production, you can rent our machine that’s available off-the-shelf. This machine is ideal to start producing small batches of batteries or to develop your own welding process. |
Additional Resources
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What is Laser Welding and How Does it Work?Discover how laser welding works by going over key principles, including conduction welding, keyhole welding, dissimilar metal welding, adjustable ring modes, and the types of lasers. |
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Laser Welding Copper: Fiber, Blue, or Green Lasers?Get the full picture on the types of lasers used for copper welding, a material that is known for its high reflectivity of infrared light. |
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How Laser Weld Monitoring Systems WorkDelve into the inner workings of LWM systems, the devices used to automatically detect bad welds in battery production lines. |
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Battery Tab Welding MethodsLearn about the welding methods that can be used to make battery tab connections, including ultrasonic bonding, laser welding, resistance welding, and micro TIG welding. |