Laser welding has established itself as the leading joining technology in battery cell production - especially where precision, speed and thermal control are crucial. Our customised solutions enable reliable, reproducible welded joints for cylindrical, prismatic and pouch cells.

DPW - Laser welding of battery cells with dynamic geometry recognition

Laser welding of busbars - efficiency and precision for electrical connections
Laser welding of busbars is a high-precision joining process that is primarily used in electromobility, power electronics and energy distribution. Busbars are used for the low-loss transmission of high currents, which is why their connection technology must fulfil the highest requirements in terms of electrical conductivity, mechanical stability and thermal load capacity. By using laser technology, copper and aluminium busbars can be joined together efficiently, quickly and in a material-friendly manner.

The process offers numerous advantages over conventional welding methods, is contactless and wear-free: the laser works without physical tool contact, which eliminates tool wear and increases process reliability.
High precision: The focussed laser beam enables exact weld seams with minimal heat input, which reduces material deformation and improves quality.
Process speed: Laser welding enables short cycle times and is therefore particularly suitable for automated production lines.
Variety of geometries: Complex welding configurations such as overlap or T-joints can be realised precisely. A typical field of application is the connection of multi-layer copper conductors in battery systems or the welding of aluminium busbars in inverters. A high-power fibre laser is often used here, depending on the material and application. Due to the increasing demand for electrical energy transmission in modern applications, laser welding of busbars is becoming increasingly important - as a key technology for durable, efficient electrical connections.

Dynamic Precision Welding - Process reliability and precision through adaptive welding strategies

In modern battery cell production, the requirements for precision, flexibility and process reliability are constantly increasing - especially when it comes to the interconnection of cell connectors and current arresters.
Laser welding with dynamic geometry recognition is a key technology for meeting these requirements.

Functional principle Dynamic Precision Welding:

Dynamic geometry recognition is based on a combination of camera technology, AI-supported image processing in real time and dynamically adaptable laser path guidance by scanners . Before the welding process, the actual position and geometry of the cell contacts, e.g. tab positions or arrester layers, are precisely recognised. Deviations from the target position (e.g. due to component tolerances, heat distortion or layer displacement) are taken into account and the welding process is automatically adjusted. This enables highly accurate and reliable contacting, even with varying component geometries.

Advantages of DPW scanner laser welding in battery cell production