SONI-SHAPE-LASER

This is the idea and how it is game-changing 

NEED/CHALLENGE

The shift to electric vehicles in niche and low-volume markets (fewer than 10,000 units per year) has created a need for lightweight, low-cost, and scalable battery packs. To meet strict safety and performance requirements, battery cases must be gas- and water-tight, durable in collisions, and often made from high-strength aluminum alloys. However, joining these aluminum parts is challenging due to their susceptibility to cracking. 

Laser welding has become the preferred method for battery cases, but the current wire-fed laser welding approach has limitations. It can be difficult to access certain areas due to the wire and nozzle setup, which restricts design flexibility, increases production costs, and reduces efficiency. These challenges highlight the need for a more advanced laser welding solution that can deliver both flexibility and cost-effectiveness in battery manufacturing.

INNOVATION

The Soni-Shape-Laser project introduces a groundbreaking, fully remote laser welding process using contactless high-frequency ultrasound and free-form beam shaping. This innovation replaces traditional wire-fed laser welding, eliminating the need for filler wires. The technology precisely controls the weld’s shape and strength by using ultrasonic vibrations to refine the material’s structure and prevents cracking. This advanced approach improves battery case welding, increases production speed, enhances flexibility, and reduces costs, making it easier to meet strict safety and sealing requirements. Additionally, the modular design allows it to be easily retrofitted into existing equipment, boosting efficiency for UK manufacturers.