Laser and Mobility Lasers Optimize the Value Chain of Battery Production

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TRUMPF Laser- und Systemtechnik SE

FAULHABER Drive Systems

According to its own statements, Trumpf increases efficiency in the production of batteries for electric cars in all areas. The laser makes it possible once again...

On the path to achieving widespread electromobility, the laser plays a crucial role, according to experts from Trumpf. Therefore, the company offers corresponding laser applications for the entire process chain of battery manufacturing, as well as for the production of electric motors and the high-performance electronics of electric cars, to cover, so to speak, the entire spectrum. At the Battery Show Europe 2025 in Stuttgart (Germany), the entire laser process chain for battery production will also be demonstrated by June 5.

Repeatable Manufacturing of Power Conductors

Laser processing is thus an essential part of battery manufacturing. In electrode production, for example, the laser precisely cuts and welds the electrode foils. In cell assembly, it ensures the highest quality and yield—especially when joining different material connections for current-carrying components, as it is further explained. And in terms of the production of battery modules and packs, the laser is the decisive tool to create fast, strong, and, above all, repeatable precise connections of the busbars. This creates a safe and stable battery.

Produce Absolutely Tight Cooling Plates in Series

With lasers, users can also reliably weld cooling plates for e-car batteries to be gas-tight in series, as Trumpf further explains. This is only possible on an industrial scale with beam shaping technology, such as Trumpf's multi-focus technology, by sending the laser light through a so-called multi-core fiber. It then goes through an optical element to a patented arrangement of multiple focal points. This beam shaping prevents pores and small holes, which would have fatal effects on the function of the cooling plates. The multi-focus technology divides the laser beam into an outer ring and an inner core. This makes it possible to distribute the laser's power very precisely, as Trumpf emphasizes. Users can thereby weld components made of stainless steel and aluminum at high speeds. The advantages are guaranteed tightness, increased efficiency in production, and precise welding results.

The Laser Aids in Battery Recycling

Batteries that have reached the end of their life cycle or are defective from the start can be disassembled using laser processes so that the valuable components and materials can be recycled and recovered, Trumpf explains on this topic. The laser precisely cuts open the battery cases and selectively dissolves existing adhesive surfaces. Additionally, the laser-based removal of coatings enables more efficient processing of scrap from electrode production. This also allows valuable materials such as lithium, cobalt, or graphite to be recovered.

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