Battery Welding with Fiber Lasers

Batteries require careful assembly to create a safe, convenient and powerful device. Most consumer batteries use crimped metal seals with a polymer sealant for their packaging. However, when the cell’s chemistry changes or more components must be attached, Lasers are the preferred tool.

What is SPI Lasers Role in Battery Production?

As batteries are made at a very high rate, sometimes well over 10 per second, the use of resistance welders or mechanical fasteners is not viable. redENERGY Fiber Lasers can optically match the speed of the moving cell and spot weld without contact, electrode wear or electrode sticking. They are a great alternative to a traditional battery tab welder or spot welding equipment.

Can Lasers Help to Create a Hermetic Seal?

For advanced cell chemistries such as Lithium cells, Lasers can create a hermetic seal to protect against water vapour damage. Laser welding a lid to the can is fast, reliable, low cost and easy to automate.

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Case Study

Typical Ni-Cd chemistry use nickel-plated mild steel components for low cost and good conductivity. Lithium cells often use stainless steel for some of their packaging. All have good metallurgy for Laser welding.

For hybrid automobile and high-tech space-based batteries, Fiber Lasers can be used to weld the many thin plates in the battery and weld or braze components together to optimise the energy per unit volume. Glass to metal feed-through pre-forms can also be Laser welded into the battery assembly to provide a hermetic package.

redENERGY Pulsed Fiber Lasers produce the necessary pulse energy and discreet pulses for spot welding cell components.

For seam welding cells for a hermetic seal then our redPOWER CW Fiber Lasers are often the best choice due to their high-speed welding capability with low heat input.

Battery welding e-mobility solutions

The world is embracing the paradigm shift of moving from fossil fuels to electric vehicles, through what is termed “e-mobility”. Batteries will be at the centre of this revolution, as they will power electric vehicles.

A range of solutions such as ablation and dissimilar metal welding will be required for every electric vehicle produced. SPI Lasers range of fiber lasers are ideal to meet this challenge.

For additional information, please read the following related articles:

Product Solution – redENERGY or redPOWER


Battery welding solutions are just the start with SPI Lasers

We have discussed battery welding here, but this is just the start. There are so many different solutions and applications, which owners of our Pulsed and Continuous Wave fiber laser modules can use. For more information, contact SPI Lasers by phoning us or completing our contact form.


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