Battery Welding Challenges

Battery manufacturing is growing exponentially, driven by technological advances across many industries. There is not only an increased demand for supply, however. Industries are requiring high performance and efficiency in battery packages that are ever more compact, in configurations that are challenging to design and construct. Reliability and safety are also key factors in modern battery design. For manufacturers and their suppliers, there’s also the pressure of maintaining development and productions schedules while also providing a cost effective, quality product.

Although responsible for only 3.9% of all car sales now, industry experts expect electric vehicles to be dominant within a generation. With the rapid proliferation of electric and hybrid automobiles there are corresponding advancements in battery design, and weld engineering is increasingly important to the development of batteries that successfully balance space limitations, heat, power and safety requirements.

The demand for modern batteries extends to other sectors as well, such as the aerospace and defense industries, where projects like drone and weapons power systems, wearable energy packs, etc., need highly specialized batteries and capacitor arrays. Renewable energy sources also require power storage systems built around batteries, again with performance and safety requirements, and configurations tailor to the specifics of the application.

Regardless of capacity or application, all batteries require reliable electrical connections and appropriate housings/packaging. Welding, and perhaps more importantly, weld engineering, are essential.