𝗥𝗲𝘃𝗼𝗹𝘂𝘁𝗶𝗼𝗻𝗶𝘀𝗶𝗻𝗴 𝗘𝗩 𝗕𝗮𝘁𝘁𝗲𝗿𝘆 𝗔𝘀𝘀𝗲𝗺𝗯𝗹𝘆

The Challenge
Delivering EV battery assembly precision at speed

Electric vehicles feature multiple battery modules, each comprising approximately 6,000 Li-Ion cells that all require the perfect weld. It is critical that every weld is precise, consistent and safe – any failure can be catastrophic.

Welding electric vehicle battery cells to busbars presents several challenges due to the unique characteristics of Li-ion batteries and the stringent safety and performance requirements in the automotive industry. The tolerance between a successful and unsuccessful weld on a battery busbar is 0.03 mm, so maximum precision is required.

Cells and associated busbars need to be clamped accurately to enable precision welding of the busbars to the positive and negative terminals of all individual cells to achieve effective electrical conductivity. This time-consuming process results in long lead times and operational inefficiencies.

MetLase collaborated closely with Hyperbat’s welding engineers to develop a unique solution to this complex engineering challenge.