Manufacturing Technology Upgrades

Under the rapid development of the new energy vehicle and energy storage industries, battery module assembly is facing unprecedented challenges and opportunities. The market has higher requirements for battery systems in terms of energy density, safety, and lifespan, while manufacturing enterprises are under pressure to expand capacity, reduce costs, and improve efficiency. With the global energy structure adjustment, the demand for power batteries and energy storage batteries continues to rise, driving the industry to transition towards smarter, higher-precision, and more flexible production models. In this context, the introduction of advanced manufacturing technologies has become key to enhancing competitiveness. Among them, laser technology plays a significant role in battery module assembly due to its high efficiency, precision, and reliability.

Manufacturing Challenges Highlighted, Laser Technology Provides Optimal Solutions

Currently, battery module assembly faces three major challenges:

1.Connection Reliability Issues – Traditional welding methods such as ultrasonic welding and resistance welding struggle with dissimilar metals like copper and aluminum, often leading to high contact resistance and insufficient welding strength, which affect the stability and lifespan of battery modules.

2.Production Efficiency and Consistency Challenges – As battery modules evolve towards higher capacity and greater integration, manual or semi-automated production methods can no longer meet market demands. Increasing production speed and yield rates has become an urgent issue for the industry.

3.Manufacturing Costs and Process Bottlenecks – Traditional processing methods involve significant consumables and post-processing steps, driving up production costs. Additionally, minimizing heat-affected zones and reducing damage to battery cells are key concerns for manufacturers.

In response to these challenges, laser technology has emerged as a leading solution due to its unique advantages. Laser welding, with its high-energy-density, non-contact processing, precisely controls heat input, enabling high-strength connections for key components such as tabs and busbars. It also supports dissimilar material welding (aluminum, copper, nickel), reducing contact resistance and enhancing battery performance. Laser cutting provides high-precision, burr-free processing, ensuring dimensional consistency for tabs and busbars. Laser cleaning is used for pre-welding surface treatment, efficiently removing oxidation layers without chemical reagents, thereby improving welding quality.

Moreover, laser technology is highly adaptable for integration into automated production lines. With vision recognition and intelligent monitoring, it enhances production consistency and yield rates, helping enterprises achieve cost reduction and efficiency gains.

To meet the industry's demand for high-efficiency, precision, and intelligent manufacturing, HGLaser has launched the Module Welding and Assembly Line. This production line provides a complete set of processes, including module automatic loading assembly, side plate welding, pole cleaning, CCD inspection before welding, busbar installation, busbar welding, CCD inspection after welding, module testing, module off-line, AGV transfer, and other essential procedures.

The entire line is integrated into the MES system and incorporates informatization, the Internet of Things, and mobile Internet to enable comprehensive production line information management and achieve full traceability of product information.

Epilogue

Battery module manufacturing is accelerating toward intelligent and flexible production, with laser technology playing a key role. As ultrafast lasers and hybrid welding mature, efficiency and quality will improve. Integrating AI and big data, laser processing enables precision manufacturing. Continuous laser innovation will drive industrial upgrades and support green energy development.

About HGTECH

HGTECH is the pioneer and leader of laser industrial application in China, and the authoritative provider of global laser processing solutions. We comprehensively layout the construction of laser intelligent equipment, measurement and automation production lines, and smart factories to provide an overall solution for intelligent manufacturing.

We deeply grasp the development trend of manufacturing industry, constantly enrich products and solutions, adhere to exploring the integration of automation, informatization, intelligence and manufacturing industry, and provide various industries with laser cutting systems, laser welding systems, laser marking series, laser texturing complete equipment, laser heat treatment systems, laser drilling machines, lasers and various supporting devices The overall plan for the construction of special laser processing equipment and plasma cutting equipment, as well as automatic production lines and smart factories.