High-Speed Production Process
The unmatched capabilities of IPG lasers, combined with systems designed specifically for battery module production, enables welding that is high-speed, high-quality, and with low heat input into sensitive components.
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Battery Busbar Welding
For all battery cell technologies, whether cylindrical, prismatic, or pouch, conductive busbars are used to connect individual cells into modules. Laser welding enables the creation of busbar-to-cell connections that meet critically important electrical performance requirements while also offering unmatched production speed, reliability, and ease of automation.
Laser Processing Provides Unique Benefits for EV Manufacturers
The Fastest Module Busbar Welding
Laser welding is capable of making more busbar-to-terminal welds per second than any other metal joining process, enabling manufacturers to dramatically increase module throughput.
Ultra-Consistent Welding Results
Laser welding is a non-degrading, non-contact process that produces consistent, high-quality welds across millions of busbar-to-terminal connections.
Highly Flexible Weld Joint Design
Laser parameters can be easily adjusted to match changing module production requirements such as weld size, shape, and pattern with no mechanical changes required.
Five Key Laser Welding Advantages for Battery Modules
Spatter & Porosity Virtually Eliminated
Weld spatter and porosity that can reduce busbar performance are virtually eliminated by dual-beam technology that allows for high welding speeds without compromising weld quality.
Extended Process Window
IPG dual-beam technology has a wider selection of laser configurations than alternative technologies, allowing for greater process optimization and reduced sensitivity to variations in cell and busbar height.
Dissimilar Material Welding Made Easy
Single-mode lasers use high power density to easily join the dissimilar materials used in busbars and cell electrodes like copper, aluminum, and nickel-coated steels with minimal heat input.
Real-Time Weld Measurement
IPG patented weld measurement technology provides highly accurate, non-destructive weld measurements on each weld as it is performed for 100% quality assurance of busbar-to-cell connections with no additional cycle time.
Learn More About IPG E-Mobility Solutions
At IPG, we are dedicated to maximizing productivity and quality in a wide range of E-Mobility applications with cutting-edge laser technologies and solutions including:
Dual-Beam Lasers that virtually eliminate weld defects like spatter while enabling higher welding speeds and increased repeatability.
Real-Time Weld Measurement that directly measures each weld as it is made for highly accurate 100% quality assurance that helps ensure battery safety.
High-Power Scanners that enable IPG fiber lasers to quickly perform a high volume of welds over a wide area, make high-quality cuts in battery foils, and more.
Get the E-Mobility GuideDiscover Your Busbar Laser Welding Solution
IPG partners with E-Mobility manufacturers throughout the entire production process from research and development to full-scale manufacturing.
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