Trumpf presents solutions for all production stages at the Battery Show

11 Jun 2025

Beam shaping safely welds heat exchangers; laser processing recycles valuable materials.

Manufacturing systems and laser maker Trumpf has this week been showcasing various laser applications for battery production process chain, for the production of electric motors and other systems for electric cars.

At the Battery Show Europe 2025 in Stuttgart, Germany, (between 9-11 June), the high-tech company has presented its solutions for the “entire laser process chain for battery manufacturing,” according to Johannes Bührle, responsible for global battery projects.

“Together with our customers, we develop customized solutions for their production in our laser application centers around the world to ensure greater efficiency and productivity in battery manufacturing,” Bührle added.

In electrode production, for example, the laser cuts and welds the electrode foils with precision. In cell assembly, the laser ensures maximum quality and yield, especially when joining different material connections of current-carrying components. In the production of battery modules and packs, the laser is the decisive tool for creating fast, strong, and, above all, repeatable connections between the busbars, described by Trumpf as “crucial for a safe and stable battery”.

Lasers also enable users to reliably weld cooling plates for electric car batteries in series production in a gas-tight manner. This can only be achieved on an industrial scale with beam shaping technology such as Trumpf’s multifocus technology.

By sending the laser beam through a multi-core fiber and then focusing it onto a patented arrangement of multiple focal points via an optical element, this beam shaping technology prevents pores and small holes that would have a fatal impact on the function of the cooling plates.

Multifocus technology divides the laser beam into an outer ring and an inner core. This makes it possible to distribute the laser power very precisely. Users can weld stainless steel and aluminum cooling plates at high speeds with this technology. “Our customers benefit from guaranteed tightness, increased production efficiency, and precise welding results,” said Bührle.

Laser-battery recycling

Batteries that have reached the end of their life cycle or are defective can be dismantled using laser processes so that the valuable components and materials can be recycled and recovered. The laser precisely cuts open battery housings and selectively removes adhesive surfaces.

In addition, laser-based removal of coatings enables efficient processing of waste from electrode production in order to recover valuable materials such as lithium, cobalt, and graphite. “These technologies contribute to more sustainable battery production,” said Bührle.