3 mins Read 
23/10/2025 Laser welding plays an important role in achieving consistent, high-quality welds across our larger, high-performance and safety-critical battery packs, such as those used in e-mobility and robotics. By combining precision welding technology with automated pressure control, we ensure each cell and busbar is joined securely, supporting the structural integrity, electrical performance and long-term reliability of every pack we manufacture.
Understanding the Challenge in Battery Pack Welding
When components are laser-welded, they must make firm and even contact before the laser pulse begins. In most systems, this is achieved using mechanical fixtures or spring-loaded holders that apply downward pressure to keep parts in place.
As part of our ongoing investment in advanced manufacturing, we introduced laser welding to enhance precision and consistency in the production of our larger, high-performance battery packs. The process allows us to achieve clean, repeatable joints between cells and busbars, supporting the electrical and mechanical reliability required for safety-critical and demanding applications.
Over time, we found that small variations in this pressure could occur, and even minor changes in welding pressure stability can influence weld depth, penetration or strength. While each weld still met specification, these variations introduced slight differences between welds that, in high-volume production, can affect overall process control. Maintaining repeatability is essential, as even small inconsistencies can lead to measurable differences in electrical resistance, thermal performance or mechanical integrity. For us, this was an opportunity to take welding process optimisation even further.
Smarter Pressure Control
IPG Photonics, the manufacturer of our EV Flex laser welder, introduced a new feature known as the Single Point Down Holder (SPDH) and we used this to address this issue. The SPDH replaces traditional spring-loaded holders with an electronically controlled arm that applies a programmable amount of downward pressure before each weld. By ensuring consistent and repeatable contact pressure every time, the system helps create consistent welds across every battery pack we manufacture.
Pressure is applied through ceramic cones or contact tips which are designed for durability and surface protection. These ceramic tips are heat resistant (up to 1,650 °C), non-conductive (eliminating the risk of short-circuiting) and non-contaminating (ensuring no foreign material is introduced to the weld). As a result, the ceramic contact tip helps prevent marking and heat transfer, protecting material surfaces during the process and ensuring consistent weld quality.
Since introducing the SPDH, we have seen clear improvements in process repeatability. For our customers, this means increased confidence in product durability and greater long-term reliability. These advancements demonstrate how automated welding systems and precision pressure control in laser welding can deliver consistent and measurable results every time, reflecting our commitment to continuous improvement, rigorous quality control, and investment in the best equipment.
Find out more about our battery manufacturing facilities or contact us to discuss your battery pack production needs.
