Pouch Cell Module – Early-Stage Engineering Support

The customer was preparing to implement a pouch cell battery module and invited us to collaborate already at the concept and design stage, understanding that reliable automation starts with a well-engineered product.

The key challenge was the joining of aluminium and copper terminals, which is technically demanding due to:

• Different melting points (Cu 1083 °C, Al 660 °C)
• Different thermal expansion behavior
• Different absorption of laser radiation
• Formation of brittle intermetallic compounds
• High sensitivity to gaps between components

Working closely with the customer’s engineering team, we applied design-for-automation principles and process expertise from the earliest project phase.

Together with IPG Photonics Polska, we planned and executed laser welding tests to define a stable joining strategy and automation-ready design.

The welding tests led to clear conclusions:

• Aluminium on copper – stable process with lower risk of unstable fusion depth
• Copper on aluminium – narrower process window, requiring higher precision
• Critical factor: gaps – gapless clamping proved essential for joint quality and repeatability

These results directly influenced both the module design and the automation concept.

Based on test outcomes, we:

• Advised the customer on module design optimized for automation
• Conducted welding tests meeting all technical requirements
• Designed and manufactured a dedicated pressing pad enabling gapless clamping
• Produced test welds and prototype joints
• Delivered a fully prepared module for functional testing

• Reduced implementation risk through early validation
• Clear design and process guidelines for automated production
• Shorter time to implementation in the next project phase

This case study shows how early involvement of an automation partner and deep technological understanding lead to robust, scalable, and automation-ready solutions, even for challenging material combinations.