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E-mobility made with TRUMPF lasers

Creating the future today.

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TRUMPF offers solutions for different fields of technology

The worldwide mobility transition is in full swing. The demand for components for electric cars and alternative drives is rising continually. Particularly high-performance components directly involved in the production of batteries, electric motors and power electronics for electromobility are at the centre. More and more companies, predominately automotive suppliers, are also demanding new manufacturing solutions and technologies for alternative drive concepts, including the fuel cell. TRUMPF provides in-depth advice to its customers and facilitates new procedures.

The laser is at the centre of many solutions. It connects battery cells with modules or packs. It ensures tightness and crash safety when joining battery packs and trays. It scores highly thanks to its green wavelength when copper welding contact parts with no spatter. And it provides high-tensile connections in e-drives which withstand the highly dynamic requirements.

TRUMPF application - battery cell busbar welding

Battery cell and modules

The laser offers many benefits in the production of lithium-ion batteries for electromobility, and has now become a significant production tool. The range of laser applications in the electrode, cell, module and pack sectors is immense. Applications such as the low-resistant contacting of live components, gas-tight sealing of battery cells as well as highly dynamic cutting of electrodes are applications worthy of special mention.

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Fuel cell

TRUMPF's laser technology is used in all drive concepts and has become an indispensable tool in many production steps. In a fuel cell drive with hydrogen, the focus is on the fuel cell stack, the heart of the system. Bipolar plates are a central component. Using laser technology, they are welded in the metallic version with the highest requirements of precision and quality.

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Battery pack and battery tray

The battery pack and the battery tray combine the components of a battery system. Tightness, crash safety and high productivity with a high level of flexibility are central criteria which facilitate the complete TRUMPF solution.

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Powertrain

Electrified powertrains must be able to withstand very high dynamic requirements. This is why high-tensile connections are an absolute must during production. TRUMPF advises its customers on planned applications for welding high-tensile steels, copper and aluminium.

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TruLaser Station 7000 laser welding automotive application

Power electronics

Whether it is Direct Copper Bonding (DCB), laser welding of IGBT boards or joining internal control unit contacts – you will benefit from the defined energy input and can rely on reproducible results when using lasers.

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E-mobility consulting - tackling the challenges of e-mobility together

Would you like to know how we can provide you with optimum support on your path to electromobility? Make an appointment directly with our internationally active branch managers. They are happy to advise you concerning our customised complete packages and facilitate new production technologies for the new mobility.

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TRUMPF is your contact for automated production processes and networked systems of the future.

TRUMPF smart factory example fpr e-mobility applications

TRUMPF stands for industry-standard complete solutions for the production of all components in a battery pack. We cover the entire sheet metal process chain with our integrated expertise. Just one example: our 2D laser cutting machines, bending machines and laser welding cells are used for manufacturing battery trays in interlinked processes.

Our integrated software solutions make it possible for you to produce with process reliability and to have seamless documentation of the production history. Furthermore, the Condition Based Services from TRUMPF increase the technical availability and productivity of your networked laser systems.

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Lightweight design

From aluminium and high-tensile steel to fibre-reinforced materials - TRUMPF lasers open up entirely new possibilities when it comes to processing lightweight materials and they shape everything precisely. They make optimal use of the material and are very flexible when it comes to the geometry.

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Battery pack and tray

Battery cells and modules

Power electronics

Powertrain

Lightweight design

Automated production solutions for e-mobility

1. Battery pack and tray

Using the laser, all interior parts of a battery as well as its housing are welded with a high degree of precision – and always with process reliability thanks to an intelligent sensor system. The precision tool is a winner in the manufacturing and integration of cooling systems in batteries as well.

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2. Battery cells and modules

Battery cells are connected into modules or packs with the busbar welding procedure. The live rail is designated as the busbar. Prismatic cells or cell modules can be combined with like materials (Al/Al or Cu/Cu) as well as with mixed combinations (for example, Al/Cu).

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3. Power electronics

You can achieve pinpoint contacting in complex electronic control units with the laser. Our lasers with green wavelength and sufficient power mean that copper contacts in electric cars can be processed highly productively and practically without any spatter.

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4. Powertrain

Whether it is a differential, hairpin, busbar, rotor shaft, gear wheel, stator or its housing – regardless of the electric drive component, laser processing makes the more compact design possible in the first place.

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5. Lightweight design

TRUMPF lasers and machine tools make many lightweight designs possible in the first place. Thanks to accurate and precise production, considerable savings can be made in terms of weight and material during the manufacture of the automobile body.

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6. Automated production solutions for e-mobility

Satisfy your material requirements with intelligent sheet metal construction for e-mobility. TRUMPF provides you with automated production solutions for this purpose which are highly productive in small or fluctuating lot sizes.

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Why TRUMPF is your perfect partner

Notable customer projects

TRUMPF advises and supports numerous customers on their path to electromobility. They benefit from our extensive expertise as a technology supplier for OEM, TIER, cell manufacturers and integrators.

Partnerships with research facilities

TRUMPF is a partner in numerous public and private research initiatives, where we develop new technological solutions for battery production.

Nothing is quite like a personal conversation: visit TRUMPF in Ditzingen

We ensure TRUMPF products are an all-embracing experience for our customers.

Whether it is in the TRUMPF& Laser Applications Center or Customer Center – our experts in Ditzingen will show you what is possible – in person and in line with your requirements. Our application specialists and industry experts will support you during application development and optimisation of your specific component in the Laser Applications Center, a centre extending over an area of 4000 m². On the other hand, you will experience the entire sheet metal process chain – from programming to laser welding – in our Customer Center. We offer individual guided tours as well as live demonstrations of the technologies. Time studies, feasibilities and generation of sample parts are also part of the core tasks.

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White paper

PDF - 451 KB

White paper: Laser welding of hairpins

Hairpins are essential in manufacturing powerful electric motors for electromobility. You will discover in our white paper how lasers provide support during production and processing. Simply fill in the form below and receive exclusive background information and more details in our white paper.

White paper: Improved coupling behavior, along with green light

PDF - 656 KB

New developments in laser welding of copper contacts, power electronics and control units in the field of electromobility

Thanks to the continuous further development of the beam sources, the application results are also improved. For example, industrial-grade lasers with a green wavelength and sufficient power enable copper contacts to be processed more productively and practically without any spatter in the field of electromobility. In our white paper, read more on the latest developments and numerous application opportunities in electromobility.

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Smart Factory

With the modular networking solutions from TRUMPF, we help our customers to create a continuous flow in their production facility, thereby arranging their entire production process with increased transparency, flexibility and cost-effectiveness within the framework of Industry 4.0.

Welding copper

Non-contact tool lasers can be used to create high-strength copper connections which are also entirely reproducible and have high conductivity.

TruDisk with green wavelength

With cw TruDisk green continuous wave lasers, you can produce copper weld seams of the highest quality, in a process that is practically spatter free and has a high reproducibility rate. Find out more about the tried and tested TruDisk disk laser technology with green laser light, its advantages and possible applications.

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TRUMPF Ltd.

Telephone +44 1582 725335

Fax +44 1582 399260

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