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Laser Welding Technology for

E-Mobility Applications

Laser Welding for E-Mobility

Leading battery and EV manufacturers are turning to laser welding for demanding E-Mobility welding applications that require excellent joint quality with high throughput and high part yield. Laser welding is a highly repeatable non-contact process that excels at creating low resistance and mechanically strong joints, even when joining copper and dissimilar materials.

As the world’s leading manufacturer of industrial fiber lasers, IPG offers the broadest range of laser types and characteristics, providing more opportunities to optimize results and productivity for E-Mobility welding applications. While every process has unique requirements and characteristics, the products and technologies below have been widely adopted by leading EV manufacturers for welding applications.

Contact an E-Mobility expert to learn more about how IPG laser solutions can optimize your E-Mobility welding applications.

Laser Welding Technology

The Clear Choice For E-Mobility Manufacturing

Highly-Focused Single-Mode Lasers

Eliminate Common EV Battery Welding Concerns

While all lasers can be focused to a small spot, “Single-Mode” lasers have a beam quality that allows them to be focused to an even smaller diameter than Multi-Mode lasers. 

Because creating a desriable keyhole weld pool usually requires high power density rather than high power alone, Single-Mode lasers allow welding with less overall power and less heat input to the part. This is a key consideration in many EV battery parts where the weld is next to temperature sensitive components, such as welding battery can lids that are in close contact with a polymer separator.

The high power density created by Single-Mode lasers rapidly melts the surface of all metals, including reflective metals like copper and aluminum, to achieve very high welding speeds.

Adjustable Mode Beam (AMB) Lasers

Enable High-Speed, High-Quality Welding

Highly focused lasers allow for high-speed and high-precision welding, even when creating copper and dissimilar metal joints, but at very high welding speeds can cause weld spatter and porosity that is unacceptable in some E-Mobility applications. AMB dual-beam lasers introduce a secondary ring beam that surrounds the focused core beam to virtually eliminate spatter and porosity, allowing manufacturers to create high-quality joints without sacrificing welding speed.


IPG AMB lasers are available in more ring-core diameter combinations than those offered by any other available dual-beam alternative, allowing configuration optimization options that increase the welding process window and, ultimately, part yield.


Because AMB technology generates the ring and core beams independently, AMB laser sources are intrinsically more reliable than competing dual beam technologies that use mechanical elements for beam separation.


High-Speed, Spatter-Free Laser Welding With AMB

Non-AMB Welding

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AMB Welding

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(2.5 mm Lap Joint (Busbar), Material: 0.5 mm Ni coated Copper + 2.0 mm Ni coated Copper)

Quasi-Continuous Wave (QCW) Lasers

Minimize Heat Input & Reduce Operating Costs

Continuous Wave (CW) lasers can be operated in pure CW mode or can be modulated to provide millisecond to microsecond pulses with the same maximum peak power. Quasi-Continuous Wave (QCW) lasers provide pulse bursts with ~10X higher peak power. QCW lasers also retain all of the benefits of CW lasers, capable of operating in pure CW mode at nominal average power output.


This higher peak power greatly increases the capability of the laser to couple with a metallic surface to produce the weld at a lower average power and with reduced collateral heating of the part, reducing operating costs and increasing weld quality.

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Combined AMB & QCW Lasers

Optimal Solution for Copper Welding

For E-Mobility applications, QCW and AMB dual-beam technology can be combined to produce a ring and core laser beam where both the ring and core may be independently operated in Continuous Wave or Quasi-Continuous Wave mode.


This QCW-AMB combination is ideal for welding highly reflective conductive elements like copper using highly reliable, energy efficient, and cost-effective IR lasers instead of less reliable, more expensive green or blue lasers.

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Real-Time Laser Weld Measurement

Ensures EV Parts Meet Quality Requirements

Although laser welding is the most stable and repeatable joining process, variances in part dimensions caused by manufacturing tolerances and other inconsistencies caused by non-laser equipment can return unexpected welding results. Robust weld quality assurance is necessary to ensure electric batteries and drivetrains perform as intended to maximize electric vehicle range and avoid costly recalls, but post-weld inspection techniques impact throughput by adding additional production steps.


IPG patented Laser Depth Dynamics (LDD) is a real-time measurement technology that measures the weld site before, during, and after welding operations without increasing cycle times. Unlike other in-process weld monitoring methods that offer imprecise or indirect measurements, LDD directly measures weld depth and 20+ other weld quality indicators for weld data consistent with destructive measurements at a micron level.

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Fiber Laser Sources for E-Mobility Welding

Ultra-Compact Lasers

Powers from 1 kW to 15 kW

Ultra-Compact Size for Easy Integration

Typical Applications:

  • Module Case Welding
  • Battery Tab Welding
  • Case Welding

 Ultra-Compact Lasers Datasheet

AMB Dual-Beam Lasers

Spatter and Porosity Free Welding


Typical Applications:

  • Battery Cell Welding
  • Busbar Welding
  • Module Case/Battery Pack Welding

 AMB Lasers Datasheet (Single-Mode)

 AMB Lasers Datasheet (Multi-Mode)

QCW-AMB Lasers

Cost-Effective, Air-Cooled Operation

Reduced Heat Spatter-Free Welding

Typical Applications:

  • Multiple Foil Welding
  • Injection Pin Seal/Welding
  • Connector Tab Welding

 QCW-AMB Lasers Datasheet

Fiber Laser Systems for E-Mobility Welding

Integrated Laser
 Welding Systems (ILWS)

  • Easily Integrated Laser Welding Systems
  • Includes Process Development
  • High-Speed, Automated Laser Welding

Learn More About ILWS

Laser Welding
R & D Workstation

Precision Process Development Workstation

Work Envelope: 500 x 300 x 300 mm

Typical Applications:

  • Prismatic Module Busbar Welding
  • Cylindrical Module Busbar Welding
  • Control Box / PDU Contact Welding

Learn More About the R & D Workstation

EV-Cube Laser Welding Busbar System

Cylindrical Cell Module Busbar Welding

Part Size up to 1100 x 1100 mm

Typical Configurations:

  • Standard & High-Speed Configurations
  • Manual Load (Pre-production)
  • Conveyor Fed (Full Production)

Learn More About the EV-Cube

Laser Welding

Flexible 2D & 3D Automated Welding

Work Envelope: 1000 X 1500 mm

Typical Applications:

  • Prismatic & Pouch Module Welding
  • Control Module / PDU Contact Weld
  • Integrated Pack & Case Welding

Learn More About the Welding LaserCell

Battery Module
Laser Welding Line

Cylindrical Module Busbar Weld & Test Production Module

Work Envelope: 1000 x 1000 x 1000 mm

Typical Applications:

  • Fully Automated Busbar Welding
  • Single or Two-Sided Welding
  • Post-Weld Electrical Test & Rework

Learn More About the Module Welding Line

Battery Module Assembly & Manufacturing Line

Battery & Electronic Module Assembly

Fully-Automated Part Handling, Assembly, & Laser Processing

Typical Functions:

  • Incoming Part Pick, Test, & Place
  • Assembly / Adhesive Steps
  • Laser Welding / Laser Processing
  • Inspection & Electrical Test

Learn More About the Module Assembly Line

Discover Your E-Mobility Welding Solution

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


Whether you want to demonstrate feasibility with laser-processed parts or just want to bounce design and implementation ideas off a laser welding specialist, don’t hesitate to contact us. Even better, visit one of our 32 regional Application Development Labs to see how IPG can optimize your EV welding applications.


Contact an E-Mobility Expert

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