Optimizing the Welding Process in the Battery Industry

A leading manufacturer of battery components faced a complex technological challenge related to welding tin-coated copper to nickel-plated copper. Due to the low boiling point of tin, the initial welding process resulted in high porosity and unstable joint quality.

An additional constraint was the presence of plastic insulating components located very close to the weld zone, which could not be exposed to excessive heat.

The customer’s objective was to achieve a stable, repeatable process suitable for high-volume serial production.

We developed a comprehensive process solution combining equipment selection, parameter optimization, and dedicated fixturing:

• Optimization of laser welding parameters, including laser power and welding time
• Design of a custom clamping system to ensure joint stability and repeatability
• Implementation of an air-blow system to improve heat management and weld quality
• Full process preparation for serial production

Extensive testing and process validation confirmed:

• Significant reduction of weld porosity
• Controlled heat input, preventing damage to adjacent plastic components
• Stable and repeatable weld quality suitable for automated production

The optimized process met all quality and production requirements and was successfully transferred to serial manufacturing.

• Reduced production costs through minimized scrap and material losses
• Increased productivity – up to 4 million joints per year without additional downtime
• Improved joint quality, ensuring high mechanical strength and electrical conductivity
• Protection of sensitive components thanks to precise thermal control
• Fast transition to mass production

A combination of deep process expertise and dedicated engineering allowed us to transform a demanding material combination into a robust, production-ready welding process, supporting the customer’s long-term scalability.