01
Design
Build reliable welds into the product from the beginning.
- Bus bar-to-cell joint design
- DFM / DFA considerations
- Material and stack-up review
- Weld geometry and location
- Tolerance and fit-up assessment
BATTERY INTERCONNECT LASER WELDING
From Weld Design to Production Validation.
Specialized technical expertise for the design, development, validation and implementation of laser-welded battery interconnects—backed by more than four decades of automotive design and manufacturing experience.
CORE SOLUTIONS
Technical support across the entire weld lifecycle.
02
Development
Turn the product requirement into a controlled laser process.
- Parameter development
- Process-window development
- Depth-of-penetration criteria and monitoring
- Porosity and defect criteria
- Defect prevention and troubleshooting
- Metrology development
03
Validation
Demonstrate that the weld meets the intended performance requirements.
- Weld acceptance criteria
- Cross-section and metallurgical review
- Electrical resistance characterization
- Mechanical and fatigue testing strategy
- Durability and reliability planning
04
Implementation
Move a validated process into a repeatable production environment.
- Equipment and integrator support
- Production ramp assistance
- Process capability assessment
- PFMEA support
- Launch troubleshooting and corrective action
PRODUCTION-LEVEL EXPERIENCE
Experience developing the requirements—not just reviewing them.
Battery Pack Assembly
Developed Contamination Specifications for Battery Pack Assembly, using lessons learned from launch, warranty and quality concerns to establish requirements to minimize isolation faults.
Bus Bar-to-Cell Criteria
Developed EV battery pack welding criteria including depth-of-penetration monitoring requirements and porosity criteria.
Strength & Durability
Developed the testing criteria for weld strength and durability and completed the associated testing to evaluate performance.
Battery Pack Welding
Compiled the first Welding Specification for battery packs, connecting technical requirements with production application.
OUR APPROACH
Connect product engineering to manufacturing engineering.
The goal is not simply to create a joint that works in a lab. The goal is to create a joint that is a repeatable process that can be measured, validated and implemented in production ensuring quality of the event.
Start a technical discussion →01Define
Understand the joint, materials, requirements and failure risks.
02Develop
Establish weld characteristics and a practical process window.
03Validate
Correlate weld quality to electrical, mechanical and durability requirements.
04Implement
Support equipment, quality, PFMEA and production launch activities.
TECHNICAL SPECIALIST
Ken Moore
42+Years Automotive Experience
15Years EV Battery Pack Manufacturing
Ken Moore has more than 42 years of automotive design and manufacturing experience, including 15 years in EV battery pack manufacturing. His background spans product and manufacturing engineering, electronics design and testing, Pack weld development, quality, durability and hands-on production launch. Quality is the #1 objective.
During his most recent employment with Ford, Ken was selected for a small team to develop the Universal Electric Vehicle (UEV) Program where he helped establish foundational battery-pack manufacturing requirements and welding criteria. His work included contamination specifications, bus bar-to-cell welding criteria, depth-of-penetration monitoring, porosity criteria, strength and durability testing, and compilation of the first battery-pack Welding Specification.
Battery Interconnects
Laser Welding
Quality
Durability
Production
CONTACT
Have a weld design, validation or production challenge?
Let's discuss the joint, the requirements and where you are in the development process.