10 reasons to choose Laser Welding tech for EV battery manufacturing

The EV market is zipping ahead. The “Electric Vehicles: Global Strategic Business Report” estimates the global market for EVs will reach 80.7 million units by 2030, growing at a CAGR of 30.7% over the analysis period 2022-2030.

The battery pack is the heart of the EV. It is what releases these vehicles from their dependence on fossil fuels. Now, these battery packs are formed of an intricate network of cells. The most popular battery pack supplied by Tesla, for instance, contains around 7000 cells capable of storing 85 kWh of energy. One defective connection can result in failure.

This brings us to joints, which are what keep the battery together. The quality of the joint is what decides the sustainability and safety of EVs and it is what prevents failure or accelerated aging of the vehicle.

Laser welding is the most promising technology to contact battery cells in EVs. It enables fast and precise production of joints primarily because they have a reduced thermal energy input as temperature increase may be harmful to lithium-ion battery cells.

According to a 2022 study titled ‘Quality assurance of battery laser welding’, low electrical resistance and high mechanical strength are key advantages of laser welding compared to other welding processes.

Here are 10 advantages to using Laser Welding technology in EV battery manufacturing

  1. Flexibility:
    The size and shape of the welds can fit into tight spaces and accommodate a variety of designs 
  2. Clean Welds:
    Laser welding produces welds that require little or no post-weld cleaning. This reduces the risk of contamination and ensures consistent quality 
  3. Precision:
    The laser beam can be focused on a small area and making it suitable for delicate or thin metals 
  4. Non-contact:
    Can be used in areas that are not easily accessible by ultrasonic or resistance welding heads 
  5. High Speed:
    Laser welding is five to ten times faster than Tungsten Inert Gas (TIG) welding 
  6. Low Heat:
    As there is no high heat input, the battery is not damaged. 
  7. Strength:
    Laser welding has low electrical contact resistance and high mechanical strength compared to other welding processes 
  8. Versatility:
    It produces strong welds for all material combinations (copper, aluminum alloys, nickel, etc) 
  9. Comprehensive:
    All types of battery cells including cylindrical cells, prismatic cells, and pouch cells benefit from using laser tech 
  10. Cost-effective:
    For example, there is no need to bevel a part before laser welding. This saves on the final cost per part. Also, since laser welding speeds up the process, the cost is reduced as there is a lower cycle time to produce a part


Blue Star E&E has partnered with Laserax to provide clients with optimal and reliable laser solutions, which are a perfect fit for high-tech industrial products. We have been delivering superior technology solutions for over six decades now in collaboration with global technology partners in the fields of aerospace, automotive, oil & gas, manufacturing and healthcare, and more. Blue Star E&E is also known for its world-class after-sales service. Give us a call or request a quote today.

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