Battery Module Busbar Welding

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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.

Contact an E-Mobility expert to learn more about how IPG laser solutions can optimize your battery module production.

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.

E-Mobility Lithium-ion battery thin metal cutting with a Laser

1. 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.

2. Spatter and Porosity Virtually Eliminated

Weld spatter and porosity that can reduce busbar performance are virtually eliminated by dual beam technology that allows high welding speeds without compromising weld results.

E-Mobility Battery Pack Welding with a Laser

3. Increased Part Yield from Extended Process Window

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.

4. 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.

Electric component processing with a laser

5. Real-Time Weld Measurement for 100% Quality Assurance

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.