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Laser Material Removal Technology for

E-Mobility Applications

For Li-ion battery and electric motor manufacturers, cleaning and material removal are highly precise operations that must ensure the processing of extremely thin material layers without damaging the sensitive underlying materials. Other surface preparation methods, such as abrasive blasting and chemical cleaning, are too rough or too time consuming to be viable solutions. Laser cleaning and laser material removal, referred to as laser ablation, is a fast and repeatable non-contact process that has become an increasingly common choice for EV manufacturers, particularly for hairpin stripping and pre-weld cleaning.

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

Laser Material Removal Technology

Optimized Laser Pulses

Tuning Laser Pulse Properties Increases Material Removal Quality & Throughput

Lasers remove surface material by emitting light continuously or in pulses of higher peak power. Laser pulsing optimizes many E-Mobility material removal applications by vaporizing thin material layers while minimizing the overall heating effect on sensitive underlying parts.


The optimization of pulse power and frequency increases the quality and speed of laser ablation in a variety of E-Mobility applications, including selective electrode decoating, pre-weld cleaning, and selective stripping of the insulation from motor hairpins. Lasers with adjustable nanosecond pulse durations are a common choice for EV manufacturers but the fine tuning of laser properties enables process optimization across a wide range of material removal requirements.

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Laser Beam Shapes & Sizes

Customized Beam Profiles Match The Ablation Task

Different ablation tasks benefit from laser beam shapes or energy profiles tailored to the application requirements. A highly focused, high energy density beam may be perfect for milling a ceramic surface while removal of oil and organic contaminants requires a less focused beam, enabling the use of a wide area beam to dramatically increase throughput.

Gaussian profiles, flat top, and round or square beams increase the process optimization opportunities by matching the laser spot shape to the processing area to maximize material removal rate.



From left to right: Gaussian, Flat Top, & Square beam profiles

Fiber Laser Sources for Material Removal

IPG offers the broadest range of nanosecond pulsed laser powers, pulse durations, and beam characteristics, providing E-Mobility manufacturers with the greatest opportunity to optimize material removal performance and throughput. While every application is unique, EV manufacturers have widely adopted IPG nanosecond lasers for ablation applications.

Nanosecond Lasers

Average Power Up to 500 W

Pulse Energy Up to 2 mJ


Typical Applications:

  • Pre-Weld Hairpin Stripping
  • Pre-Weld Tab & Contact Cleaning
  • Selective Electrode Decoating

 Air-Cooled Nanosecond Lasers

Nanosecond Lasers

Average Power Up to 2 kW

Pulse Energy Up to 2 mJ

Highly Flexible Material Removal

Typical Applications:

  • Seal-Pin Pre-Weld Cleaning
  • Pre-Weld Contact & Case Cleaning
  • Pre-Weld Electrolyte Remvoal

 High-Power Nanosecond Lasers

Ultra High-Power 
Nanosecond Lasers

Average Power Up to 3 kW

Pulse Energy Up to 100 mJ

High Throughput Material Removal

Typical Applications:

  • Paint Stripping
  • Pre-Weld Contact & Case Cleaning
  • Equipotential Bond Weld Preparation

 Ultra High-Power Nanosecond Lasers

Fiber Laser Systems for E-Mobility Material Removal


Automated Cleaning & Material Removal

Work Envelope: 1000 x 1500 mm

Typical Applications:

  • Battery Module Pre-Weld Cleaning
  • Inverter Module Pre-Weld Cleaning
  • Coating Removal for Connectivity

Learn More About the Ablation LaserCell

Discover Your E-Mobility Material Removal 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 material removal specialist, don’t hesitate to contact us. Even better, visit one of our 30 regional Application Development Labs to see how IPG can optimize your material removal applications.


Contact an E-Mobility Expert

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