Automated Laser Welding Solution for EV Battery Electrodes
In April 2025, SFX LASER-LYXCTECH received an inquiry from a U.S. customer seeking an automated solution for mass welding of new energy (EV) battery electrodes, aiming to replace traditional resistance welding.
Challenge
Conventional resistance welding presented several issues:
- Large heat-affected zone
- Risk of burn-through and over-welding
- Difficulty welding aluminum and thick copper
- Fast electrode wear
- Spatter and weak welds in multi-layer applications
Solution Validation
After initial discussions, the customer provided battery samples for testing. Led by Wang Heng, the engineering team conducted multiple rounds of testing and validation.
Results confirmed that laser welding is a viable solution, meeting all requirements in:
- Welding quality
- Efficiency
- Joint strength
- Electrical conductivity
Custom Machine Development
Based on the proven results, SFX LASER developed a customized solution using the enclosed platform laser welding system DLW-2000A as the foundation.
The system features:
- 7-axis motion control
- Automated programming
- High-precision repeat positioning
- Integrated safety protection
Additional customized functions include:
- Pressing mechanism: Automatically secures electrode tabs before welding for stable contact
- Vision positioning system: Detects placement deviations and auto-corrects welding positions
- Dust & fume extraction system: Maintains a clean internal environment during continuous operation
- Customized safety interlocks: Meeting specific customer safety requirements
Result
The customized machine was assembled and tested in May 2025, fully meeting all technical requirements. After remote video inspection, the customer approved the system’s design, usability, and performance.
The machine was delivered in June, and the customer later confirmed high satisfaction with its performance in real production.
Key Takeaway
This project highlights SFX LASER’s capability to deliver highly automated, customized laser welding solutions for advanced battery manufacturing applications.
