Pouch Cell Module – Early-Stage Engineering Support | Case Study

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 stage of the project. This approach reflects the importance of understanding when production automation should start – before the product design and production concept are fixed, when engineering decisions can still reduce complexity, technical risk and future implementation costs.

Together with IPG Photonics Polska, we planned and executed laser welding tests to define a stable joining strategy for aluminium and copper terminals. Our experience in laser welding automation allowed us to evaluate the joining process not only from the perspective of weld quality, but also its future repeatability, scalability and suitability for automated production.

A key focus of the engineering work was product design and clamping in laser welding. The trials demonstrated how material arrangement, gaps between components and the clamping method directly influenced process stability. These findings were used to refine the module concept and develop an automation-ready design with appropriate conditions for repeatable welding.

This early validation formed an important foundation for future battery module and pack automation, where cell and terminal geometry, material combinations, positioning accuracy and process accessibility must be considered before the automated production system is developed.

The project therefore connected product design, process development and future automation requirements at the concept stage, reducing the risk of discovering critical limitations later in the implementation process.

A related copper laser welding case study shows the next stage of this approach, where laser parameters, dedicated fixturing and thermal management were optimized to create a stable and repeatable welding process suitable for high-volume serial production.

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.