Electrical Components & Modules

Electrical Components & Modules

In addition to batteries, vehicle electrification requires additional electrical components such as inverters, control boxes, and power distribution units (PDUs) to handle the flow of electrical signals and currents to the drivetrain components. Fiber lasers enable the welding of the inter-component connectors and busbars to meet critically important performace requirements while also offering unmatched production speed, reliability, and ease of automation.

Laser Welding Provides Unique Benefits for EV Manufacturers

High Quality, Low Resistance Connections


Laser welding easily overcomes the common challenges of welding copper, aluminum, nickel-coated steels, and steel alloys to create high-quality joints that optimize electrical properties with minimal heat input.

High Yield & Throughput


Laser welding is faster than other welding methods and is easily integrated with automation and process control like real-time weld quality assurance that measures critical weld parameters without increasing cycle times.

Tooling Flexibility


Laser welding only requires single-sided access, greatly reducing manufacturing complexity and tooling requirements when welding electric components like inverters, busbars, and power distribution units.

Five Key Laser Welding Advantages
for Electronic Components & Modules


Dissimilar Material Welding Made Easy

Single-mode lasers use high power density to easily join dissimilar materials frequently used in contact-to-busbar connections with minimal heat input, simultaneously protecting nearby heat-sensitive components.


Spatter & Porosity Virtually Eliminated

Weld spatter and porosity, which increase the risk of short circuits in electronic components, are virtually eliminated by dual-beam technology that minimizes weld defects without reducing welding speed.


Extended Process Window

Adjustable Mode Beam (AMB) dual-beam technology is more configurable than alternative dual-beam technologies, ensuring high-quality contact-to-busbar joints across a wider range of part variances.


High-Speed, Cost-Effective Welding

Air-cooled Quasi-Continuous Wave (QCW) lasers use burst of high peak power to rapidly achieve the required weld depth in thicker busbars at lower average powers, reducing overhead costs without sacrificing welding speed.


Real-Time Weld Measurement

IPG real-time weld measurement provides in-process contact-to-busbar weld data that enables the consistent creation of low resistance joints by guarding against process drift.

IPG E-Mobility Solutions

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 Guide

Discover Your Electrical Component Welding Solution

IPG partners with E-Mobility manufacturers throughout the entire production process from research and development to full-scale manufacturing.

Ready to get started? Send us a sample for evaluation or your product specifications and our laser experts will recommend a laser solution that best matches your application.

Get an Application Evaluation

Solutions for Other E-Mobility Applications

Li-ion Cell Manufacturing

Li-ion Cell Manufacturing

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Battery Packs & Trays

Battery Packs & Trays

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Electric Motors

Electric Motors

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Battery Modules & Busbars

Battery Modules & Busbars

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How Can We Help?

Whether you have a project in mind or just want to learn more about laser solutions for welding electronic components, an IPG laser expert is ready to help.