Laser Processing Technology in Lithium Battery Manufacturing: Revolutionary Applications and Future Trends

Ⅰ.Introduction: Laser Technology Empowers Efficient and Intelligent Battery Production

Laser processing technology, as an advanced manufacturing method, is highly compatible with the production requirements of lithium batteries, and its application in lithium battery equipment is growing rapidly. Currently, laser technology is used across multiple stages of lithium battery production, including electrode manufacturing, cell assembly, and module/PACK integration. Key processes include laser cutting, welding, cleaning, and marking. By 2025, the global market for laser processing equipment in lithium batteries is projected to exceed $5.8 billion, with a CAGR of 18.7%, making it a core driver of industry advancement.

Ⅱ.Four Core Laser Processes and Their Applications

1. Laser Cutting: Precision Shaping of Electrodes

Technical Advantages:

• Cutting precision: ±10μm; burr height <5μm; electrode utilization rate >98%.

• Non-contact processing eliminates material deformation or contamination.
  Applications:

• Electrode slitting (Cu/Al foils): Damage-free cutting for ultra-thin materials (6μm Cu).

• separator cutting: Heat-affected zone (HAZ) width <20μm, preventing melt residue.

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2. Laser Welding: Seamless Cell Encapsulation

Breakthroughs:

• Blue laser (450nm) for copper welding: 65% absorption rate (vs. 5% for IR lasers).

• Speed: 300mm/s; porosity <0.5%; strength >200MPa.
  Applications:

• Cylindrical cells: 4680 tab welding (yield >99.9%).

• Prismatic cells: Aluminum case sealing (leak rate <0.1ppm).

3. Laser Cleaning: A Green Manufacturing Revolution

Highlights:

• Pulsed fiber laser removes electrode residues at 1m²/min, reducing energy use by 70%.

• Chemical-free process compliant with RoHS/REACH.
  Case Study:

• Substrate pre-cleaning: Surface roughness Ra reduced from 0.8μm to 0.2μm.

• Oxide removal pre-welding: Increases weld strength by 30%.

4. Laser Marking: Enabling Full Lifecycle Traceability

Value Proposition:

• High-contrast permanent marks (10–50μm depth), resistant to heat (>500°C) and electrolytes.

• QR/DataMatrix codes enable cell-level traceability (IATF 16949 compliant).
  Applications:

• Cell ID marking: Unique codes with 15-year data retention.

• Process parameter logging: Records welding voltage, temperature, etc.

Ⅲ.Conclusion:Redefining Lithium Battery Manufacturing with Laser Technology

With the advantages of high precision, high efficiency and high flexibility, laser processing technology is fully penetrating the core link of lithium battery manufacturing. With the maturity of ultrafast laser, AI collaboration, green technology and other technologies, laser equipment will become a key pillar of the lithium battery industry towards the TWh era.