EV Battery Welding & Battery Manufacturing

Laser welding and laser cleaning are among the most promising technologies for EV battery welding. Lasers provide the speed and precision required for the thousands of welds in battery packs, battery modules, and cells. As a green technology, lasers are also in line with the objectives of the e-mobility industry.

Unlike alternatives, all types of battery cells can benefit from laser technology, including cylindrical cells, prismatic cells, and pouch cells. Laser welding and cleaning are being implemented for a wide range of electric vehicles:

  • Cars
  • Trucks
  • Taxis
  • Bicycles
  • Busses
  • Motorcycles
  • Four wheelers
  • Jet skis
  • Airplanes
  • Boats
  • Ships
  • Forklifts
  • And much more...

 

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Why Choose Laser Welding Technology?

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    High Speed Automation at Lower Cost

    Lasers are not a small investment, but the return on investment is fast in high volume production lines. Not only are they low in maintenance, but the laser power can be scaled as needed to optimize the cleaning and welding speed. Lasers are also often chosen for their ease of automation.

  • Improved Electrical Conductivity

    Metals joined by laser welding have an excellent electrical conductivity as they are fused together. The result is minimal resistance and better heat management at the welded joints.

  • Custom Welding Patterns 

    Because lasers are a non-contact technology, welding patterns can be optimized for each application. This guarantees strong and reliable bonds regardless of the welding area’s size, shape, or location.

  • Improved Welding Quality 

    Through a precise control over the heat input, laser welding provides high quality and repeatable results. When developing solutions for our clients, we run several tests to validate the welding quality including the electrical and mechanical resistance. Quality tests also include a cross section visual exam to identify defects.

     

  • Quick Configuration Changes

    Laser parameters can be updated automatically for different battery needs. This is ideal if you are working with multiple battery assemblies, or for the cell assembly when you need to weld various components such as battery cans, tabs, safety vents, cover plates, or the cell’s rigid case. The laser welding process can also be updated on the fly so that the laser beam is adjusted for different material thicknesses.

  • Welding of Dissimilar Metals

    Lasers can be used to weld dissimilar materials with varying fusion temperatures, such as steel-copper, steel-aluminum, aluminum-copper, and steel-nickel. These interconnections are essential for many battery manufacturing applications and are made possible by the variety of laser wavelengths.

  • Surface Preparation for Welding

    Fiber lasers can prepare tabs and busbars for welding by removing contaminants like hydrocarbon, electrolyte, varnish, epoxy, and oil. You get a clean surface for welding, which guarantees the quality of the electrical contact and the overall weld strength.

Industrial Laser Welding & Cleaning

Battery Laser Cleaning Machine

Battery cleaning machines can be installed directly on conveyors to clean hundreds of cells while the battery pack is moving on the conveyor.

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High-power laser system

High-Power Fiber Laser Welder

Laserax provides turnkey solutions powered by high-power fiber laser welding systems. Our systems are specifically made for battery applications and include a digital scanner technology that shuts down the laser in the rare case of an optical misalignment. 

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