Challenges and Opportunities for Laser Applications in Electric Vehicle Manufacturing

Ali Gökhan Demir, Johannes Kriegler, Alessandro Fortunato, Leonardo Caprio, Christian Geiger, Lucas Hille, Michael Karl Kick, Alessandro Ascari, Erica Liverani, Michael F. Zaeh

Research output: Chapter in Book/Report/Conference proceedingChapterpeer-review

3 Scopus citations

Abstract

The ever-growing demand for electric vehicles in the world and Europe will result in a significant socio-economical change. The electrification changes the material types, usage, manufacturing, and vehicle design. The contemporary electric drives are being used in various vehicles, such as automobiles, drones, trains, airplanes, and ships. These vehicles will require a lower weight, an extended maximum range, and faster recharging as the number of vehicles in use increases. Compared to vehicles powered with combustion engines, fewer components will be placed with increased demand in flexible welding, heat treatment, cutting, trimming, and texturing applications. The need for rapid changes in the vehicle models and the variety of components will be resolved through highly digitalized, flexible, adaptable, and reliable manufacturing processes. From this point of view, laser-based manufacturing is an essential solution, placing this family of processes as the conventional method in electric vehicle manufacturing. Today, lasers are used in various applications, such as hairpin stripping and welding, cutting and texturing of Lithium-ion electrodes, welding of battery busbars, and cutting of composite materials. The rapid reduction of the costs of laser sources, optics, and components in the last decade facilitated the adoption of laser systems in electric vehicle manufacturing. Although laser technology has reached the required maturity, the system developers and the end-users still need to catch up with the pace of the growing demand in electric vehicle manufacturing. This white paper highlights the challenges and opportunities regarding the main laser-based manufacturing processes for electric vehicle production.

Original languageEnglish
Title of host publicationLecture Notes in Mechanical Engineering
PublisherSpringer Science and Business Media Deutschland GmbH
Pages219-253
Number of pages35
DOIs
StatePublished - 2024

Publication series

NameLecture Notes in Mechanical Engineering
VolumePart F1351
ISSN (Print)2195-4356
ISSN (Electronic)2195-4364

Keywords

  • Battery modules
  • Cutting
  • Digital tool
  • E-mobility
  • Electric drive
  • Industry 4.0
  • Lithium-ion battery
  • Texturing
  • Welding

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