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:

  • Electric vehicles (cars, taxis, etc.)
  • Electric commercial vehicles (forklifts, trucks, buses, airplanes, ships, etc.)
  • Recreational electric vehicles (motorcycles, bicycles, four wheelers, jet skis, boats, etc.)
  • Energy storage systems


Ask an expert

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.

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.

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.

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.

Battery Laser Welding Machine

  • For full scale battery production
  • High-power laser (up to 6kW of laser power)
  • Fiber laser technology (1,070 nm wavelength) with continuous-wave laser beam output
  • Complete solution (clamping, vision, weld monitoring, rework, contaminant management, laser safety, etc.)


View Machine

Battery Laser Welding Workstation

  • For small batches, R&D, and laser process development
  • Available for rent or purchase
  • Easy to operate
  • Same laser as the battery laser welding machine (for a transition into full-scale production without unknowns)


View Machine

Battery Laser Cleaning Machine

  • Can prepare tabs and busbars for ultrasonic bonding or laser welding while battery modules or packs are moving on a conveyor
  • Removes all types of contaminants, including hydrocarbon, electrolyte, varnish, epoxy, and oil
  • The cleaned surface guarantees the quality of the electrical contact and the overall weld strength
  • 50W-200W of laser power (typical configuration)
  • Fiber laser technology (1,064 nm wavelength) with pulsed laser beam output


View Machine

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.

Marc-Antoine Gagnon, Application Specialist

Laser Welding Services for Battery Manufacturing

Laser Welding Process Development

Each 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.

Request Service

Laser Welding Service

We 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.

Request Service

Laser Welding Machine Rental

Before 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.

Request Service

Additional Resources


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.

Learn More

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.

Learn More

How Laser Weld Monitoring Systems Work

Delve into the inner workings of LWM systems, the devices used to automatically detect bad welds in battery production lines.

Learn More

Battery Tab Welding Methods

Learn about the welding methods that can be used to make battery tab connections, including ultrasonic bonding, laser welding, resistance welding, and micro TIG welding.

Learn More

Let's Work Together

Ready To Get Started?

Tell us about your application