SONI-SHAPE-LASER PUBLIC DESCRIPTION

     One of the major hurdles in Electric Vehicle (EV) adoption is the high cost, partly from the lack of flexibility/reconfigurability in battery pack production. To tackle this, Soni-Shape-Laser aims to offer an optimised commercial solution with a novel approach to laser welding 6xxx aluminium, commonly used in battery casings. We're committed to advancing the UK supply chain and existing technologies for customised battery packs through flexible manufacturing. 

     A vital component is the casing, designed for robust integration and safety in crash protection and thermal events. 

     Supported by this grant, our laser welding technology aims to promote flexibility/fast reconfigurability in battery pack production, achieving efficient manufacturability, and a viable modular/scalable pack design.

     To address challenges associated to limited manufacturing flexibility/reconfigurability, Soni-Shape-Laser incorporates advanced technologies such as Power-Ultrasonic Vibration Treatment (PUVT) and free-form beam shaping. 

     Useful for working with 6xxx aluminium alloys, known for high crack sensitivity, the integration of these technologies set a new industry benchmark and transition from wire-fed to a fully remote and autogenous (no wire) laser welding for hermetically sealed joining of battery casings. Soni-Shape-Laser will demonstrate at least a 20% increase in productivity, 50% faster changeovers with enhanced flexibility/reconfigurability, improved access to confined welding areas, 15% weight saving enabled by more intense use of aluminium, and 20% energy/cost saving and reduced emissions.

 The target markets are niche or low-volume (<10,000/year) vehicle industry demands low-cost battery-packs and acceptable weight with a scalable battery pack architecture.