As electric mobility, renewable energy, and portable electronics expand rapidly, the demand for high-performance battery packs continues to grow. A key factor in battery reliability is how cells are connected into modules. Laser welding has emerged as the go-to method for precision, speed, and performance, and RMA is leading this transition with advanced laser automation
solutions.
Modern battery production needs to be efficient and precise. Whether joining aluminium tabs, copper busbars, or battery enclosures, laser welding provides a clean, non-contact, high-speed alternative that reduces thermal distortion and enables welding of dissimilar metals.
Selecting the right joining technology is critical for battery performance, safety, and long-term reliability. Each welding method has its place in production, but they differ significantly in precision, thermal impact, material compatibility, and scalability.
In addition, laser welding provides outstanding design flexibility, seamless integration with automated production systems, and the ability to access hard-to-reach areas without physical tool contact. These advantages make it the ideal solution for highly automated, high-volume manufacturing environments where both productivity and uncompromising weld quality are essential.
| Technology | Material Compatibility | Heat Input | Precision | Speed | Automation Suitability | Key Limitations |
|---|---|---|---|---|---|---|
| Ultrasonic Welding | Best for thin foils and tabs | Very low | Moderate | High | Good | Limited depth, weaker joints in thicker materials |
| Resistance Spot Welding | Steel good; copper & aluminum challenging | Moderate to high | Low to moderate | Moderate | Moderate | Inconsistent with conductive or thick materials |
| Arc Welding | Wide range of metals | High | Moderate | Low | Limited for high-volume precision work | Large heat-affected zone, risk of distortion |
| Laser Welding | Excellent for copper, aluminum, and dissimilar metals | Low and highly controlled | Very high | Very high | Excellent | Higher initial investment, requires process expertise |
Welds in < 0.1 seconds. Machines like RMA Battery Welder Max are built for high-volume production with automation and real-time QC.
High beam focus = accurate, spatter-free welds with minimal thermal impact.
Laser welds create strong, conductive joints suitable for high-current EV batteries.
All models run on the intuitive BW Interface software for weld configuration and traceability.
RMA supports clients through its Laser Application Center (LAC), offering full-cycle support—from prototyping to ramp-up. Expertise in fixture design, monitoring, and validation ensure production-ready processes.
RMA solutions are used by European battery leaders. Benefits include reduced downtime, improved weld quality, and support for innovation.
As electrification accelerates, laser welding will remain a key enabler of scalable, reliable battery production. RMA is committed to advancing the future of energy through innovation.
Cylindrical (18650, 21700), prismatic, and pouch cells are all compatible.
Yes. With focused heat and non-contact operation, it’s among the safest techniques.
As low as 0.1 seconds per weld with optimized systems like RMA BW Max.
Absolutely. RMA offers fully automated platforms with robotic handling and inline QC.
Looking to improve your battery production process? Get in touch with RMA for a free laser welding consultation.
