Automotive industry's shift towards low-emission electric vehicles and induce a huge demand for EV-batteries. Along the entire process chain of Li-battery production you will find a variety of potential new or already established laser applications which are crucial for the output of GW battery capacities. Within electrode manufacturing there is the already established laser cutting and notching with ns lasers but also new developments like laser-based drying processes by VCSEL or other diode emitters which are getting high attention. These technologies offer dedicated advantages in surface heating of coated electrode foils by IR-laser radiation resulting into a significant reduction of operating and energy costs and hence to a decrease of CO2 footprint. In cell assembly laser welding of demanding materials such as copper and aluminum are still essential for the entire battery system to secure technical functionality like electric conductivity, strength, and tightness. A common approach for internal connection of stacked foils combines both, a pre fixation of stacked foils by ultrasonic welding followed by laser welding to ensure highest electric conductivity. In addition, new laser-based production solution trends in cell assembly like e.g., media-tight welding of cover assembly in prismatic cell housing “Can-Cap” and busbar welding will be exemplified to meet highest quality and productiveness.
Finally, in battery module and pack manufacturing laser and combined sheet metal manufacturing processes are key elements in smart factory solutions. Ground breaking new technologies like multi focus beam shapes open new horizons in e.g. gas tight welding of aluminum battery heat exchangers.