Laser welding and cutting solutions in the field of battery new energy industry

Pain points and advantages of laser technology in the new energy industry
The core pain points in the manufacturing of new energy batteries (lithium batteries/energy storage/power batteries) include burrs on the electrode plates, welding virtual welding, thermal deformation, poor sealing, and insufficient flexibility.
Core advantages of laser processing:
Non contact: No mechanical stress, no damage to the pole piece/diaphragm
High precision: cutting ± 10 μ m, welding ± 0.02mm positioning
Low heat impact: HAZ<20 μ m, preventing thermal damage
High efficiency: cutting at 90m/min, welding at 1-5m/min
Flexibility: One click changeover, compatible with multiple specifications of batteries
2、 Laser welding solution (full process coverage)
1. Welding of battery cell segments (square shell/cylinder/soft pack)
Extreme ear welding (copper/aluminum 0.1-0.5mm)
Solution: MOPA pulsed fiber laser (200-300W)+galvanometer high-speed welding
Effect: Single point 0.05s, yield 99.5%+, no splashing, low internal resistance
Top cover sealing welding (aluminum shell/steel shell)
Solution: Continuous fiber laser (1000-2000W)+circular spot
Effect: Air tightness ≤ 1 × 10 ⁻⁶ Pa · m ³/s, no cracks, deformation<0.1mm
Laser welding for sealing the top cover of new energy batteries
Sealing nail/injection port welding
Solution: Fiber laser (500-1000W)+visual positioning
Effect: Reliable sealing, no leakage, compatible with automated production lines
Laser welding of sealing nails for new energy batteries
2. Welding of modules/PACK sections
Busbar welding (copper/aluminum 1-3mm)
Solution: High power continuous laser (2000-4000W)+dual laser head
Effect: Melting depth ≥ 1mm, low resistance, suitable for high current, yield 99.8%+
Module shell/side panel welding
Solution: Robot Fiber Laser Welding Machine+Offline Programming
Effect: Smooth weld seam, minimal deformation, efficiency of 12-15PPM, traceable
Battery tray/shell welding (aluminum alloy 5-10mm)
Solution: Gap adaptive laser welding (1mm gap adaptive)+five axis linkage
Effect: No polishing required, cost reduced by 30%, speed increased by 3 times, deformation reduced by 80%
3、 Laser cutting solution (polarizer/diaphragm/structural component)
1. Polar laser cutting (core process)
Solution: Picosecond/femtosecond ultrafast laser+high-speed flight cutting+CCD vision
effect:
Burr<3 μ m (traditional die-cutting ≥ 15 μ m)
Edge without carbonization, roughness Ra<0.6 μ m
Speed 90m/min, 5-minute changeover, yield 99.9%+
2. Diaphragm/insulation sheet cutting
Solution: UV/femtosecond laser+non-contact cutting
Effect: No stretching, no cracks, no internal short circuits, compatible with PP/PE materials
3. Cutting of battery structural components (tray/cover plate/explosion-proof valve)
Solution: Five axis laser cutting machine+3D programming
Effect: Accuracy ± 0.05mm, one-time molding, efficiency improvement of 200%, adaptability to complex hole positions
4、 Di Nai Laser Special Solution (Highly Recommended)
As a national high-tech enterprise founded by a doctoral team from the Chinese Academy of Sciences, Denai Laser is deeply involved in the field of new energy batteries and provides customized laser welding/cutting line solutions
Extreme ear welding machine: MOPA pulse laser, suitable for 0.1-0.5mm copper aluminum extreme ears, with a yield rate of 99.5%+
Top cover sealing welding station: 2000W continuous laser, circular spot, air tightness meets the standard
Polar laser die-cutting machine: femtosecond laser, no burrs, speed 80m/min
Battery tray welding production line: Suitable gap welding technology, 1mm gap adaptive, cost reduction and efficiency improvement
Module PACK welding robot: six axis linkage, compatible with busbar/shell welding
New energy battery laser welding machine
5、 Typical application cases
4680 large cylindrical battery: pole ear laser welding+ultra fast cutting of pole pieces, yield increased to 99.7%, cycle life extended by 15%
Energy storage battery PACK: Double laser head welding of busbar+five axis cutting of tray, efficiency increased by 40%, cost reduced by 25%
Soft pack battery electrode: femtosecond laser cutting, burrs<3 μ m, no diaphragm damage, eliminates micro short circuits
6、 Selection suggestions
Welding: MOPA pulse (200-300W) is selected for the pole ear; Top cover/busbar selection continuous fiber optic (1000-4000W)
Cutting: Select picoseconds/femtoseconds (10-50W) for the polarizer; Structural component selection optical fiber (3000-6000W)
Automation: Prioritize integrating visual positioning, robots, and MES traceability to adapt to large-scale production