F.A.Q

The Soni-Shape-Laser project creates a new laser welding solution that helps battery manufacturers make their production more flexible and cost-effective. This makes it easier to design modular battery packs, which can be adjusted to different needs. By promoting battery manufacturing, the project also supports the shift to a carbon-neutral economy, protects jobs, and keeps battery production in the UK. This helps the UK become a leader in advanced manufacturing for the net-zero future, using technology developed locally. 

The Soni-Shape-Laser project team includes three UK-based small businesses and an academic partner. CARRS leads the project with expertise in laser technologies and contactless laser-assisted ultrasonic vibration. WMG, an academic partner, contributes its research strength and knowledge in advanced laser welding. IONETIC specialises in designing modular and scalable battery packs, and POWERPHOTONIC brings expertise in laser beam shaping. Together, they combine their skills to create innovative solutions for battery manufacturing. 

The Soni-Shape-Laser project is innovative because it builds on two previous successful research projects, UltraMAT and Soni-Laser, to improve laser welding and battery manufacturing. It takes these technologies from a test level (TRL 6) to a level ready for industry use (TRL 9). This means it’s developing new, practical tools that can be used in real factories, which could greatly improve how battery packs are made and change the market. 

The Soni-Shape-Laser project is designed to quickly turn its new technology into commercial products. By working closely with IONETIC, a partner with experience in the battery market, the project has a fast track to reach customers and meet current market demand. This partnership helps ensure that the technology will be available and useful to businesses sooner.  

The Innovate UK SmartGrant is important because it helps the Soni-Shape-Laser project move from testing to commercial production. Although past projects made progress, they were limited by budget and scope. At this stage, the technology is still seen as high-risk for big investments because it hasn’t been fully proven in a real-world setting. The SmartGrant fills this gap, allowing the project to move forward quickly and safely, giving it a strong advantage in the market and helping it achieve good returns on investment. 

The Soni-Shape-Laser project works closely with IONETIC, a partner with existing clients and OEMs (original equipment manufacturers). This partnership helps make sure that the new welding technology meets the technical and practical requirements of customers. By focusing on what customers need, the project increases its chances of success and makes it easier to bring the technology to market. 

The Soni-Shape-Laser project creates a modular laser welding technology that can be easily added to existing equipment and customised for each type of battery pack. This helps the niche and low-volume vehicle industry reduce costs, increase flexibility, and have more design options. The technology is also useful for welding high-grade aluminum in other areas, like automotive, aerospace, and medical fields, as well as in cutting, additive manufacturing, and cladding. There are ready customers for this technology in the UK, with export opportunities in Europe and North America.