EV Battery Welding

Overview and Applications

With increasing interest in electric vehicles, there is more and more demand for Electric Vehicle Batteries and EV Packs. Lithium-Ion batteries are currently the most common chemistry used when building EV Battery packs due to their energy to density ratio. Manufacturers can produce lighter, more compact battery packs without compromising power or capacity.

One of the biggest challenges when welding EV Batteries is finding a welder capable of welding highly conductive metals such as copper and aluminum. Inside a lithium-ion battery are various copper and/or aluminum components that carry the electrical current (such as buss bars). These components are commonly joined to either similar or dissimilar materials to facilitate the electric current. If the joint is not made properly, there is a potential for voltage drops due to the resistance between the two pieces.

Regardless of the specific requirements of a particular application, our experts have developed multiple welding solutions for welding EV Battery cells and packs. To learn more about these options, please Contact Us.

Features and Benefits of Sunstone EV Battery Welders:

  • Solderless Connections - The metals are fused together at the weld spot for a continuous connection and no voltage drops.
  • Clean Weld Spots - During the welding process, surface contaminates are burned off, allowing for strong, clean welds.
  • Weld Dissimilar Metals - Sunstone Spot Welders can weld any combination of metals, such as Copper to Aluminum.
  • Small Heat Affected Zone - The heat affected zone (HAZ) is very small and very localized to ensure no degradation to the battery. The Orion provides enough energy to make the weld without affecting the integrity of the cell.

For more information about welding EV Batteries and High-Capacity Packs, please Contact Us.