In April 2025, ZAC Laser received a technical inquiry from a customer in the United States who needed an automated solution for welding new energy battery electrodes to replace their traditional resistance welding process.
Resistance welding often leads to large heat-affected zones, burn-through, rapid electrode wear, and unstable weld quality, especially when welding aluminum or thick copper materials. The customer was therefore looking for a more stable and automated welding method.
After receiving battery samples from the customer, ZAC Laser engineers conducted multiple welding tests. The results confirmed that laser welding could meet the required welding strength, efficiency, and electrical conductivity.
Based on these results, ZAC Laser developed a customized solution using the DLW-2000A enclosed platform laser welding machine. Several custom functions were added to meet the customer’s production needs, including a pressing mechanism to stabilize the electrode sheet, a vision positioning system to correct welding alignment, a dust extraction system, and additional safety interlock features.
The customized machine was completed in May and approved after remote inspection by the customer. In June, the system was delivered and successfully put into operation.