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Whether you need a laser system with custom specifications or simply want to learn more about laser processing, an IPG e-mobility expert is ready to help you find your laser solution.
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Battery Module Welding Systems
Automated Cell-to-Busbar Welding
14 Cells Welded Per Second
Configurable Turnkey System
Automated Module Welding
Battery Module Welding Systems are fully-automated workstations for welding busbars for battery cell modules.
Configurable for either manual or conveyor-fed part loading, these systems are suitable for process development, prototyping, and low-volume production welding. Using IPG fiber lasers and optimized laser path programming, IPG battery module welding systems achieve welding speeds up to 14 cylindrical cells per second.
Configurable for either manual or conveyor-fed part loading, these systems are suitable for process development, prototyping, and low-volume production welding. Using IPG fiber lasers and optimized laser path programming, IPG battery module welding systems achieve welding speeds up to 14 cylindrical cells per second.
14 Cells Welded Per Second
Configurable Turnkey System
Automated Module Welding
Battery Module Welding Systems are fully-automated workstations for welding busbars for battery cell modules.
Configurable for either manual or conveyor-fed part loading, these systems are suitable for process development, prototyping, and low-volume production welding. Using IPG fiber lasers and optimized laser path programming, IPG battery module welding systems achieve welding speeds up to 14 cylindrical cells per second.
Configurable for either manual or conveyor-fed part loading, these systems are suitable for process development, prototyping, and low-volume production welding. Using IPG fiber lasers and optimized laser path programming, IPG battery module welding systems achieve welding speeds up to 14 cylindrical cells per second.
Optimized Battery Module Welding
As experts in both laser welding and the e-mobility industry, IPG offers the process development, programming, and application knowledge to ensure fast deployment and optimized system performance. Optional tooling development services further increase part yield for cylindrical, prismatic, or pouch cell designs.
Optional real-time weld measurement directly measures the depth of each weld as it is made for effortless 100% quality assurance. Verification of penetration depth into the cell casing of every Li-ion cell prevents catastrophic part failures and recalls, allowing for more confidence in each battery before it leaves the factory.
Battery Welding Flexibility
Fiber lasers are an excellent choice for welding common battery materials including copper, aluminum, nickel, stainless steel, nickel-plated steel, and nickel-plated copper.
The system accommodates modules up to 1 x 1 m as heavy as 450 kg, with options for manual part load or conveyor pass-through with automated entry and exit doors. Flexible system architecture accommodates rapidly evolving battery design and material selections.
Fiber Lasers & Beam Delivery Matched to Your Application
Matching the laser and beam delivery to the battery welding application is critical for increasing productivity and part quality. As the world leader in laser solutions for e-mobility applications, IPG offers a wide range of fiber laser sources and beam delivery optimized for battery welding.
- Lasers Optimized for Your Application: Continuous wave, quasi-CW, pulsed, and Adjustable Mode Beam.
- The Broadest Range of Dual-Beam Lasers: Single-mode core powers up to 3 kW for the fastest cell-to-busbar welding available.
- Integrated Beam Delivery: High-power IPG welding heads including fixed beam, scanning beam, and wobble welding.
Discover Your Next Laser Solution
Our application engineers, developers, and scientists are available across dozens of global state-of-the-art IPG application centers to help with everything from process development and optimization to full scale production.
Getting started is easy — send us a sample for evaluation or just tell us about your project and we'll take it from there.
Granite Base
Battery module welding systems are built with a granite base for vibration dampening and structure stiffness that enable high-stability busbar welding.
Linear Motors
Linear motors increase positioning accuracy and system speed, ensuring precise weld placement and maximizing battery throughput.
Easy-to-Use Software
Software is preloaded and tested at IPG prior to shipment and provides the user with a comprehensive, easy-to-use programming and operator interface.
Real-Time Weld Quality Assurance
Optional real-time weld measurement directly measures every weld as it is made to enable 100% weld quality assurance. This patented in-process weld monitoring technology eliminates the need for time-consuming and destructive post weld testing and tracks weld dimension data to warn for process drift.
Full verification of penetration into the cell casing guards against catastrophic part failures and product recalls.
Battery Module Welding System Comparison
 |  |
| EV-Cube System | EV-Flex System |
| EV-Cube System | EV-Flex System |
| Cell Type | |
|---|---|
| Cylindrical, Prismatic, Pouch | Cylindrical, Prismatic, Pouch |
| Welding Speed | |
| 14+ Cells per Second | 4+ Cells per Second |
| Max Module Size | |
| 1100 L x 1100 W x 600 H | 1200 L x 1000 W x 300 H |
| Materials | |
| Aluminum, Copper, Steel, Dissimilar | Aluminum, Copper, Steel, Dissimilar |
| Weld Position Accuracy | |
| ±50 μm | ±250 μm |
| XY Positioning Repeatability | |
| ±10 μm | ±10 μm |
| Module Loading | |
| Manual or Conveyor Pass-Through | Manual or Conveyor Pass-Through |
| Tooling | |
| IPG Custom-Designed Tooling | IPG Custom-Designed Tooling & 3rd Party Tooling |
| Control Software | |
| HMI2 | Siemens 3-Axis PLC Control |
| Dimensions | |
| 2600 L x 2200 W x 1800 H mm | 3500 L x 2500 W x 2900 H mm |
| Learn More | Learn More |
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| Cell Type | Cylindrical, Prismatic, Pouch | Cylindrical, Prismatic, Pouch | ||||
| Welding Speed | 14+ Cells per Second | 4+ Cells per Second | ||||
| Max Module Size | 1100 L x 1100 W x 600 H | 1200 L x 1000 W x 300 H | ||||
| Materials | Aluminum, Copper, Steel, Dissimilar | Aluminum, Copper, Steel, Dissimilar | ||||
| Weld Position Accuracy | ±50 μm | ±250 μm | ||||
| XY Positioning Repeatability | ±10 μm | ±10 μm | ||||
| Module Loading | Manual or Conveyor Pass-Through | Manual or Conveyor Pass-Through | ||||
| Tooling | IPG Custom-Designed Tooling | IPG Custom-Designed Tooling & 3rd Party Tooling | ||||
| Control Software | HMI2 | Siemens 3-Axis PLC Control | ||||
| Dimensions | 2600 L x 2200 W x 1800 H mm | 3500 L x 2500 W x 2900 H mm | ||||
| Learn More | Learn More | |||||
The specifications above represent standard system configurations. IPG can offer customized specifications upon request.
