Laser Welding Machine | DIY Solar Power Forum

I've seen a lot of DIYers end up in a bind with laser welded terminals where something goes wrong and now they are out of luck and/or their favorite DIY cell is only available with weld-on terminals.

Being the nerd I am, I've bounced around the thought of buying a used IR laser welder (the same type they use for cells) for the shop. If we had some sort of "job-shop" type of service and could source custom, super high quality bolt terminals, offer repairs, or even assemble custom battery packs - would it catch anyone's interest?

Previously, being a welder by trade, it kills me deep down to see things get broken but not have the tools to put it back together. I see many guys that either break or get no terminals and can't put a cell to use because all the welding equipment is in China.

Just a super crazy Sunday night thought, but I'd love to see what the forum can take and imagine with it.

Being the nerd I am, I've bounced around the thought of buying a used IR laser welder (the same type they use for cells) for the shop. If we had some sort of "job-shop" type of service and could source custom, super high quality bolt terminals, offer repairs, or even assemble custom battery packs - would it catch anyone's interest?

Every job shop I have gotten a quote from really relies on a huge markup to cover one-off projects. Then you get into the UL issues...

There should be a meaningful market for it, but it can spiral out of control quickly. There is (or was) a custom electrical switchgear company in Vegas (there are still several others around across the Southwest and Utah) that you might want to talk to about partnering with on something like this. A custom shop might be able to actually UL label some things as well for low volume production without screwing up the economics too much. Was this post spurred on by my post mentioning me popping the cap of of a Calb cell? That was totally my fault. My batteries were built to have mostly the same configuration and parts to about a 1/8 to 1/4 inch of tolerance. So on my second battery I was trying to get a chunky 4/0 cable to attach to the fuse block while it was already attached to the cell. Tolerances were working against me and too much pressure and the welds gave way. The first battery went together like a hand in a glove.


So in subsequent batteries I learn to spend more time with a vise along with a ratchet wire bender attachment and in the fetting process. Also to attach the wire to the fuse block (or shunt) FIRST. And then to the cell.

But yeah, the ability to get this repaired would be awesome. Could use it in a trolling motor battery if nothing else.

Edit: I think the one that I popped was actually the positive wire that connects to the contactor and cell 16 in the photo.

Edit 2: Only reason why I had them in that configuration was to fit eight of them in this cabinet:

Was this post spurred on by my post mentioning me popping the cap of of a Calb cell? That was totally my fault. My batteries were built to have mostly the same configuration and parts to about a 1/8 to 1/4 inch of tolerance. So on my second battery I was trying to get a chunky 4/0 cable to attach to the fuse block while it was already attached to the cell. Tolerances were working against me and too much pressure and the welds gave way. The first battery went together like a hand in a glove.

View attachment
So in subsequent batteries I learn to spend more time with a vise along with a ratchet wire bender attachment and in the fetting process. Also to attach the wire to the fuse block (or shunt) FIRST. And then to the cell.

But yeah, the ability to get this repaired would be awesome. Could use it in a trolling motor battery if nothing else.

Edit: I think the one that I popped was actually the positive wire that connects to the contactor and cell 16 in the photo.

Edit 2: Only reason why I had them in that configuration was to fit eight of them in this cabinet:

View attachment

When that happened, I bet it went with a gasp, then unintelligible syllables, then outright profanity. Been there.

When that happened, I bet it went with a gasp, then unintelligible syllables, then outright profanity. Been there.

I really only get angry when I can’t find a tool. Because it reminds me of instead of having a shop or garage, I lived like a migrant for 20 years out of boxes serving a foundation built on lies, deceit, and all for nothing and probably of which hampered us from having children (US Army). But I am digressing to politics at this point.

It’s weird. If break something expensive, it really doesn’t bother me. But God help me if I can’t find something I know I have three of. I look like a cartoon with steam whistles coming out of my ears.

FWIW I would have just used #1 AWG for the short cables. Voltage drop isn't an issue and your terminations should be good for a 90C free air rating.

Yeah, I’d there is ever a ver 2.0, I’ll probably drop them down to at least 2/0. I was running out of time to get these put together due to visa expiration in my wife’s home country and had a hard date to fly back. I had the wire and 4/0 connector bits.

I really only get angry when I can’t find a tool. Because it reminds me of instead of having a shop or garage, I lived like a migrant for 20 years out of boxes serving a foundation built on lies, deceit, and all for nothing and probably of which hampered us from having children (US Army). But I am digressing to politics at this point.

It’s weird. If break something expensive, it really doesn’t bother me. But God help me if I can’t find something I know I have three of. I look like a cartoon with steam whistles coming out of my ears.

At work I know where everything is down to the area each drawer in a large toolbox. I also know where stuff is in the building that’s bigger than a Costco. When I get home, in a little square foot house I can’t find a thing because of family. Mind blown, tosses hands in the air and just buys another. I decided to collect one kind of item to put away when I find them.Pop rivet tools. The count? Six! Who the freak needs six?

Was this post spurred on by my post mentioning me popping the cap of of a Calb cell? That was totally my fault. My batteries were built to have mostly the same configuration and parts to about a 1/8 to 1/4 inch of tolerance. So on my second battery I was trying to get a chunky 4/0 cable to attach to the fuse block while it was already attached to the cell. Tolerances were working against me and too much pressure and the welds gave way. The first battery went together like a hand in a glove.

So in subsequent batteries I learn to spend more time with a vise along with a ratchet wire bender attachment and in the fetting process. Also to attach the wire to the fuse block (or shunt) FIRST. And then to the cell.

But yeah, the ability to get this repaired would be awesome. Could use it in a trolling motor battery if nothing else.

Edit: I think the one that I popped was actually the positive wire that connects to the contactor and cell 16 in the photo.

Edit 2: Only reason why I had them in that configuration was to fit eight of them in this cabinet:

You aren't the first one to do that. I did it on 3 cells by accident (I was putting studs in, then the nuts added more torsion on the stud and did the same thing. No wonder the CALB bus bars are so flexible!!!


Obviously the cost of equipment is a factor...

At work I know where everything is down to the area each drawer in a large toolbox. I also know where stuff is in the building that’s bigger than a Costco. When I get home, in a little square foot house I can’t find a thing because of family. Mind blown, tosses hands in the air and just buys another. I decided to collect one kind of item to put away when I find them.Pop rivet tools. The count? Six! Who the freak needs six?

I now have my dad’s stuff (would be 76), my dad’s friend’s stuff (Korean war vet). I now have enough pipe wrenches to outfit a local plumbing union.

The bad…still not organized.
The good? Enough old rusty things to keep me entertained with restorations and rUstorations for the rest of my life.

My dad was also a gunsmith/restorer so I got five lifetimes of various files. And since most file manufacturers went to shit, that’s a very good thing.

Yeah, I’d there is ever a ver 2.0, I’ll probably drop them down to at least 2/0. I was running out of time to get these put together due to visa expiration in my wife’s home country and had a hard date to fly back. I had the wire and 4/0 connector bits.

I see that you pre-bended and held the cable in shape before you crimped the lugs.(impossible to do what you did without ripping strands) Ancor cable is the best conductor but the stiffness, then welding cable and the easiest to bend is silicone jacket.

You aren't the first one to do that. I did it on 3 cells by accident (I was putting studs in, then the nuts added more torsion on the stud and did the same thing. No wonder the CALB bus bars are so flexible!!!


Obviously the cost of equipment is a factor...

I’m paranoid of damaging the terminals. Only 4Nm torque and no turning the cables. Those laser welds just look fused, no filler added. Just a melted surface. All my cables are pre-bent crimped with spring back accounted for. Yeah OCD [
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While I love the idea, I fear some of the logistics will get in the way.

To ship bare cells, in theory the person packing at both ends need some sort of hazmat shipping certification or training (I'm not exactly sure in the process other than to say our shipping manager did it last year)
This hazmat shipping is horrendously expensive.

Lastly, can you make enough money on this to even pay off the tool? If you charge $100 per weld, that would cost nearly as much as some cells and still take you years to get some payback.

Sorry to be a wet blanket, but you should do it! Forget money, do it because it is cool.

While I love the idea, I fear some of the logistics will get in the way.

To ship bare cells, in theory the person packing at both ends need some sort of hazmat shipping certification or training (I'm not exactly sure in the process other than to say our shipping manager did it last year)
This hazmat shipping is horrendously expensive.

Lastly, can you make enough money on this to even pay off the tool? If you charge $100 per weld, that would cost nearly as much as some cells and still take you years to get some payback.

Sorry to be a wet blanket, but you should do it! Forget money, do it because it is cool.

A realistic response in this day and age

All my cables are pre-bent crimped with spring back accounted for

That's a really nice configuration if you ever need to top-balance in the future.

Forget money, do it because it is cool.

Well, if we have it, then nothing stops us from using it for other things that can make money...heck the sheet metal shop I used to work at had a 2-million dollar laser for sheet metal - that didn't stop us from cutting ninja stars on lunch break!

While I love the idea, I fear some of the logistics will get in the way.

It's probably true...but FYI it's not quite as expensive as you might thing once you get contract rates in place with a reputable shipping company.

Are you in the market for the perfect laser welding solution for your Li-Ion battery production? Let’s face it – laser welding is crucial for ensuring battery integrity and efficiency. But the process can be tricky, with precision, speed, and cost being top concerns for manufacturers. Do you feel overwhelmed by all the options and technical jargon? Fear not! I’m here to guide you step-by-step to make the best decision for your business needs.

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Laser welding offers unparalleled precision and efficiency, especially in the manufacturing of Li-Ion batteries. It’s a game-changer in battery production, ensuring reliable performance and long-lasting results. But with so many machines on the market, how do you know which one fits your needs? Well, that’s where I come in – I’ll break it down for you. Let’s dive into the world of laser welding machines and see what makes them the go-to choice for Li-Ion battery manufacturers.

When it comes to welding Li-Ion batteries, precision is key. Any mistake in the welding process could lead to inefficiencies, battery failures, or even safety hazards. Laser welding ensures the accuracy needed for the delicate components in a battery. The heat-affected zone (HAZ) is minimal, meaning there’s less chance of damaging the sensitive parts of the battery. Plus, it’s fast – perfect for high-volume production.

Why Laser Welding is Perfect for Li-Ion Battery Manufacturing?

Laser welding is an ideal solution for Li-Ion batteries because it offers a combination of speed, precision, and control. The thin metals in the battery components require precise welding, which traditional methods like TIG or MIG welding simply can’t provide. A laser welding machine’s ability to focus a high-energy beam into a tiny spot allows for extremely detailed work, ensuring that the parts are welded together without compromising their integrity.

But that’s not all. Laser welding is also incredibly fast and efficient, making it a great choice for mass production . The ability to automate the process means that you can produce large quantities of Li-Ion batteries quickly without sacrificing quality. Add to that the fact that laser welding generates minimal heat, and you’ve got a process that’s not only precise but also safer for the batteries themselves.

The Basics of Laser Welding

Laser welding uses a high-intensity, focused beam of light (laser) to melt and fuse materials together. The laser beam delivers concentrated energy to a small area, creating a strong, localized weld without excessive heat spread. For Li-ion batteries, this precision is critical because the components are often thin, delicate, and sensitive to heat.

Key Steps in Laser Welding for Li-ion Batteries

1. Material Preparation:

   • The components to be welded, such as copper or aluminum tabs (for anodes and cathodes) and the battery casing (often aluminum or steel), are cleaned and aligned. These metals are commonly used due to their conductivity and compatibility with Li-ion chemistry.
   • Proper alignment ensures the laser can target the exact joint.

2. Laser Beam Application:

   • A laser (typically a fiber laser or pulsed laser) emits a beam that is directed onto the joint area. The wavelength and power are tuned to the specific metal properties (e.g., copper reflects more light than aluminum, requiring higher energy or specific wavelengths).
   • The beam rapidly heats the metal surface to its melting point, forming a small molten pool.

3. Fusion and Solidification:

   • As the laser moves along the joint (or pulses in place), the molten metal from both parts fuses together. The process is often done in a controlled atmosphere (e.g., with inert gases like argon) to prevent oxidation, which is especially important for battery reliability.
   • Once the laser moves away, the molten pool cools and solidifies quickly, forming a strong, seamless bond.

4. Control and Precision:

   • Advanced systems use real-time monitoring (e.g., cameras or sensors) to adjust the laser’s power, speed, and focus. This ensures consistent weld quality, avoiding defects like cracks or porosity that could compromise the battery’s performance and safety .

Why Laser Welding for Li-ion Batteries?

• Precision: The laser can target tiny areas (e.g., welds less than 1 mm wide), ideal for small battery components.
• Minimal Heat Damage: Li-ion batteries contain heat-sensitive electrolytes and separators. Laser welding’s focused energy minimizes the heat-affected zone (HAZ), reducing the risk of damaging these materials.
• Speed: It’s fast, enabling high-throughput production for industries like electric vehicles (EVs) and consumer electronics.
• Strength and Conductivity: The welds maintain excellent electrical conductivity, crucial for efficient current flow in the battery.

Applications in Li-ion Batteries

• Tab-to-Terminal Welding: Connecting electrode tabs to the battery terminals.
• Can Sealing: Sealing the metal casing of cylindrical or prismatic cells after assembly.
• Busbar Welding: Joining cells in a battery pack for EVs or grid storage.

How Does Laser Welding Work for Li-Ion Batteries?

In simple terms, laser welding involves focusing a high-powered laser beam onto the surfaces of the materials you want to join. The energy from the laser melts the metal, which then cools and forms a solid bond. The process can be highly controlled, with parameters like power, speed, and focus adjusted to suit the specific requirements of the materials involved.

In the case of Li-Ion batteries, laser welding is used to join the metal terminals and connections to the battery cells. The process ensures that the weld is strong enough to handle the high temperatures and pressures batteries experience during use, while also minimizing the risk of short circuits or other issues.

Key Factors to Consider When Choosing a Laser Welding Machine

When choosing a laser welding machine for your Li-Ion battery production, there are several factors you need to consider to ensure you get the best value for your investment. Here are a few key things to keep in mind:

1. Precision and Control: Li-ion batteries involve small, delicate components like thin metal foils (e.g., copper or aluminum) and intricate connections. Laser welding delivers a highly focused beam, allowing for precise welds with minimal heat spread. This reduces the risk of damaging sensitive battery materials or causing thermal stress, which could compromise performance or safety.

2. Speed and Efficiency: The process is fast, enabling high-throughput production —a critical factor in meeting the growing demand for Li-ion batteries in electric vehicles (EVs), consumer electronics, and energy storage systems. Laser welding can complete complex welds in milliseconds, boosting manufacturing scalability.

3. Strong, Reliable Joints: Li-ion batteries require robust electrical and mechanical connections to ensure long-term reliability and conductivity. Laser welding produces high-quality, consistent welds with excellent penetration and minimal defects, reducing the chances of failure during operation.

4. Minimal Material Distortion: Unlike traditional welding methods (e.g., resistance or ultrasonic welding), laser welding generates a smaller heat-affected zone (HAZ). This minimizes distortion or warping of thin battery components, preserving their structural integrity and ensuring tight tolerances.

5. Versatility: Laser welding can handle dissimilar metals (like copper and aluminum, commonly used in battery tabs and terminals) and varying thicknesses. This adaptability is essential for the diverse designs and configurations in Li-ion battery packs.

6. Clean Process: It’s a non-contact method that doesn’t require consumables like filler materials or electrodes, reducing contamination risks. In battery manufacturing, where purity is critical to prevent short circuits or chemical reactions, this is a major plus.

   Additional reading:
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   If you want to learn more, please visit our website Cylindrical Lithium Battery Laser Welding Machine.

7. Safety and Automation: Lasers can be easily integrated into automated production lines, improving consistency and reducing human error. This is vital for Li-ion batteries, where manufacturing defects could lead to safety issues like thermal runaway .

The Right Laser Welding Machine for Li-Ion Batteries

So, how do you select the best laser welding machine for your Li-Ion battery production? It’s all about finding the right balance between precision and affordability. You want a machine that can deliver the exact quality and performance you need, but you also don’t want to overspend on features you won’t use.

There isn’t a single "perfect" laser welding machine for lithium-ion (Li-ion) batteries that fits every scenario, as the ideal choice depends on specific application needs, such as battery type (cylindrical, prismatic, or pouch), material composition, production scale, and precision requirements. However, I can outline the key features and considerations that define a top-tier laser welding machine for Li-ion battery manufacturing, based on current industry standards and technology trends as of March 19, .

Key Features of an Ideal Laser Welding Machine for Li-ion Batteries

1. Laser Source Type:

   • Fiber Laser: Widely preferred for Li-ion battery welding due to its high beam quality, efficiency, and versatility. Quasi-continuous wave (QCW) or continuous wave (CW) fiber lasers are excellent choices, offering precise control for welding thin, reflective materials like copper and aluminum, common in battery tabs and busbars .
   • Power Range: Typically 200W to 300W for cylindrical/pouch cells, 1kW to 4kW for prismatic cells or thicker busbars, and up to 6kW for heavy-duty applications. Higher power suits thicker materials or faster production, but lower power (e.g., W) is often sufficient for precision welds on thinner components without excessive heat damage.

2. Precision and Beam Quality:

   • A small focal spot diameter (e.g., 20-50 µm) ensures high welding power density and precision, critical for delicate battery components like tabs (0.2-0.6 mm thick) and sealing welds. Galvanometer systems enhance this by enabling rapid, accurate beam positioning, boosting efficiency by 3x or more compared to traditional setups.

3. Material Compatibility:

   • Must handle dissimilar metals (e.g., copper to aluminum) and high-reflectivity materials effectively. Fiber lasers with wavelengths around - nm are standard, though some advanced systems pair them with blue lasers (450 nm) for better copper absorption, reducing spatter and improving weld quality.

4. Welding Speed and Automation:

   • Speeds of 80-120 mm/s or higher (e.g., 18 m/min in some systems) are ideal for high-volume production, like EV battery packs. Integration with automated lines, including 5-axis motion systems or robotic arms, ensures scalability and consistency .

5. Monitoring and Quality Control:

   • High-definition CCD vision systems for real-time positioning and defect detection (e.g., porosity, cracks) are essential. Advanced setups include laser weld monitoring with AI to analyze each weld and enable immediate rework, ensuring reliability in safety-critical applications.

6. Thermal Management:

   • Minimal heat-affected zones (HAZ) are crucial to avoid damaging sensitive battery components like electrolytes or separators. Systems with power ramping, pulse shaping, or wobble motion welding heads help control heat input and produce clean, strong welds.

7. Flexibility:

   • Modular designs that adapt to various battery formats (e.g., , , prismatic) and weld patterns (spot, seam, spiral) are highly practical. Customizable fixtures and large-format worktables accommodate different pack sizes.

8. Reliability and Maintenance:

   • Maintenance-free lasers with high photoelectric conversion efficiency (e.g., fiber lasers) reduce operating costs. Stable power output and durable components ensure consistent performance over long production runs, enhancing cost-effectiveness .

Top Contenders (General Examples)

Based on these criteria, here are characteristics of machines that stand out in the field:

• High-Precision Gantry Systems: Machines like the Kirin Laser Lithium Ion Battery Laser Welding Machine offer galvanometer-based welding, 5-axis control, and compatibility with multiple cell types, ideal for large-scale production.
• Automated Production Line Integration: Kirin Laser Battery Laser Welding Machine excels with its fast cycle times (e.g., 100 ms per cell), vision systems analyzing 150+ cells at once, and full automation, making it a powerhouse for EV battery modules.
• Handheld or Compact Options: For smaller operations or field repairs, a W handheld fiber laser welder (e.g., DP Laser’s model) provides flexibility and precision for welding tabs or small modules, though it sacrifices some automation benefits.

Recommendations by Use Case

• Mass Production (EV/Pack Assembly): A W-W CW fiber laser with gantry structure, vision systems, and high-speed galvanometer.
• Small-Scale/Prototyping: A W-W QCW fiber laser with manual loading and CCD monitoring (e.g., DP Laser or WinAck models).
• Specialized Precision (Thin Tabs/Seals): A 200W-300W QCW fiber laser with a small spot size and wobble head for minimal HAZ.

Final Thoughts

The "perfect" machine aligns with your specific needs—material thickness, weld strength, production volume, and budget. For a general-purpose, future-proof option, a W-W fiber laser system with galvanometer, automation compatibility, and advanced monitoring strikes a balance between performance and versatility. If you’d like a tailored recommendation, feel free to share more details about your battery type or production goals!

Challenges in Li-Ion Battery Laser Welding and How to Overcome Them

While laser welding is an excellent choice for Li-Ion battery manufacturing, it’s not without its challenges. Some of the common issues you might face include heat damage, contamination, or inconsistent weld quality.

One way to minimize heat damage is by carefully controlling the laser’s power and speed . This helps ensure that the heat-affected zone remains as small as possible, reducing the risk of battery degradation. Contamination can be avoided by maintaining a clean workspace and using high-quality materials.

Inconsistent weld quality is another potential issue. However, modern laser welding machines come equipped with advanced monitoring systems that help ensure consistent results every time. By adjusting parameters like power, speed, and focus, these systems help ensure that your welds are always up to spec, improving weld reliability .

Future of Laser Welding in Li-Ion Battery Production

The future of laser welding in Li-Ion battery production looks incredibly bright. With advancements in laser technology, we’re seeing machines that can offer even more precision and power than before. One of the most exciting trends is the development of high-speed laser welding systems, which can dramatically increase production efficiency while maintaining quality.

Another emerging trend is the integration of artificial intelligence (AI) into the welding process. AI-powered systems can optimize laser settings in real-time based on feedback from sensors, leading to even more accurate and efficient welding. As these technologies continue to evolve, we can expect even greater improvements in the quality and efficiency of Li-Ion battery production.

Want more information on Pouch Lithium Battery Laser Welding Machine? Feel free to contact us.

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