Lithium-ion batteries are safety-critical products. Modern batteries place high demands on joining technology: reliable welded connections cell-to-cell, cell-to-busbar, busbar-to-PCB and cell-to-sensor must ensure minimal contact resistance, be vibration-resistant and withstand mechanical loads in the long term. Added to this are minimal heat input, real-time monitoring of weld penetration depth into the cell terminal, and joints between different metallurgical combinations of copper, aluminium, stainless steel and nickel.
BBW Lasertechnik supports you as an experienced contract manufacturer with precise laser material processing at the highest level. We produce batteries for various cell geometries (pouch, cylindrical, prismatic) – from individual modules and compact battery packs to complete energy storage systems (Battery Energy Storage). Where required, we deliver hermetically sealed housings and offer certified cleanroom processes. Our innovative laser welding processes ensure reproducible, vibration-resistant joints with minimal contact resistance – from prototype to scalable series production.
Thanks to nearly 30 years of experience in laser material processing, we maintain an overview even with complex requirements. Beyond partially or fully automated manufacturing of battery modules, we offer innovative automation solutions as well as support in the design and development of batteries for a wide range of applications, such as autonomous vehicles and aircraft (AGV, UAV), power tools, material handling, electric mobility, as well as defence and aerospace.
We are your partner for: automotive manufacturers, battery manufacturers, suppliers to the battery industry, research institutes for new battery technologies, engineering offices in process and electrical engineering, as well as utility companies.
Choose an experienced development and production partner for the battery solution of your products!
We process cylindrical, prismatic and pouch cells and respond quickly to new requirements thanks to a broad technology portfolio and modular machines. Since the availability and designs of battery cells change frequently, our lines can be quickly reconfigured – ideal for prototypes, samples and small to medium-sized series. This flexibility ensures short response times and optimised time-to-market cycles for you.
With decades of experience in laser material processing, we achieve precise and reproducible welded connections. Intelligent real-time monitoring of every weld seam and online monitoring of weld penetration depth safeguard the process throughout. We use advanced technology – including beam shaping and green laser for demanding copper processing at cell terminals, cathode and anode tabs.
We have deliberately expanded our capacity in battery manufacturing and produce with scalable automation depending on the quantities required. Our in-house modular systems keep initial costs low and increase the efficiency of our production processes. Local manufacturing in Germany is of great importance, especially for safety-critical battery applications.
Innovative laser processes are precise, flexible and gentle on materials – ideal for the high requirements of safety-critical battery systems.
They enable complex geometries without tool wear and reproducible joints between different metallurgical combinations of Cu, Al, stainless steel and nickel.
Low heat input and intelligent real-time monitoring of weld penetration depth reliably protect the cells against thermal damage during every process step.
The result is safe, durable and vibration-resistant connections for your batteries – from individual modules to complex energy storage systems.
BBW Lasertechnik accompanies you from the initial idea to the series production of your battery system. Beyond partially or fully automated production, we already provide support in design and development – for example for autonomous vehicles and aircraft (AGV, UAV), power tools, material handling, electric mobility, as well as defence and aerospace. Alongside state-of-the-art laser processing such as laser welding, precision laser cutting and surface processing, we have our own jig and machine construction, mechanical processes such as turning and milling, comprehensive sheet metal processing as well as precise assembly. Certified quality management with an integrated metallographic laboratory and high-voltage testing ensures safe and sustainable results at all times. Innovations in laser technology continuously flow into our processes.
Thanks to our fully networked in-house processes, you have seamless transparency over all steps – from design and industrialisation through to delivery – and benefit from a dedicated contact person at BBW Lasertechnik. This way we enable efficient workflows, short throughput times and consistently high quality – even for large quantities and safety-critical battery applications.
Do you have an idea or a concrete project you would like to realise? Contact us today for a non-binding inquiry.
Our team will carefully review your requirements and develop a suitable solution together with you – individual, efficient and reliable. Start the dialogue now and let us realise your project together.
For customers in the material handling sector, we manufacture mobile battery storage units tailored precisely to the respective requirements. For this purpose, we have built up a partially automated line that covers all steps: from laser cutting and bending of the sheet metal components, through pre-assembly of the cell connectors, to the precise welding of the housings and the cells with the cell connectors into a complete battery module.
State-of-the-art laser welding technology with weld penetration depth measurement and visual camera inspection is used. Continuous online process monitoring ensures that every process step is fully documented and verified. Finally, every assembly undergoes a 100 % voltage test. This way we ensure maximum safety and uncompromising quality in mobile series use at our customer.
High-quality, safe welded connections on battery cells as well as solid and durable system housings are basic requirements for use in public transport.
In this example, prismatic LTO cells from TOSHIBA are processed. First, the surfaces of the terminals are cleaned by laser – corrosion and contamination are removed. This ensures a defined, precise and high-quality connection during welding. The weld geometry and the monitoring of the laser beam welding depth into the cell terminal are also critical here.
After the current collectors have been contacted, the cells are merged into assemblies on our partially automated line and the electronics are subsequently integrated.
For electric aircraft, we manufacture assemblies based on pouch cells under high requirements for safety, quality and process stability. Already during the development phase, we support the customer with design adjustments to ensure a weld-friendly and production-friendly layout.
Production includes laser cutting and sheet metal processing of the components, followed by pre-assembly, laser welding and final assembly. By using multiple welding fixtures, we achieve short cycle times and a stable series. Continuous process monitoring and comprehensive quality inspections ensure the necessary traceability of all process steps.
The project particularly focuses on rapid development and qualification of processes within a few months, as well as the safe implementation of the multi-step assembly sequence.
