Since founding Danecca 5 years ago, our focus on breaking down barriers to electrification has led us to develop a huge range of capabilities in battery and high power electronics assembly.  Here's why we invested in our Laser welding capability, and how it can help you make a better product.

Laser welding has been increasingly used in the automotive industry in recent years, its ability to produce high-quality, reliable and durable bonds, along with its high throughput, contribute to increased productivity and reduced costs.  However, due to high investment costs, most battery companies offering bespoke or niche product have been unable to offer this to their customers, instead opting for spot welding, or manual techniques instead.

We looked at the benefits that laser welding would give our clients and took the leap.  Here's some of the reasons.

1. Design freedom.  Unlike spot welding, with our focusable optics, the laser head doesn't have to come into contact with the busbar, MOSFET or cell that is being bonded, we only need a line of sight to it.  This unlocks far more flexibility of design, allowing for higher power density inverters, junction boxes and battery packs.  Laser welding also allows the joining of dissimilar metals, allowing the designer to select the optimum materials for the application.
2. Versatility, Precision and Strength.  The system that we selected has a very high energy density, with variable pulse frequency and path geometry, meaning that we can process copper, aluminium and steel, in thicknesses from 10s of microns to a centimetre.  The penetration depth and width are highly controllable, giving us the ability to use it for bonding sensor circuits, high current busbars or even structural brackets and housings.  
3. Quality, Performance & Cost.  Compared with bolted joints, a laser weld has reduced impedance, leading to lower heat generation and higher efficiencies.  It also produces high-quality welds with minimal distortion, reducing the likelihood of defects and rework in the manufacturing process.  The production process is also simplified, as it doesn't require any surface preparation or filler materials.

We offer contract manufacturing, or full design services for battery and power electronic assembly from our UK facility in Silverstone.  Get in touch to discuss how we can help you get to market quicker.