Laser Cutting Techniques in Lithium-Ion Battery Manufacturing
Summary
Laser cutting has emerged as a pivotal method for the precise singulation of electrodes and current collectors in lithium-ion battery production. By delivering high-energy beams to selectively ablate thin metal foils and coated electrode sandwiches, laser systems achieve non-contact processing that minimises mechanical stress, tool wear and particle contamination. Advances in beam delivery—through continuous-wave and pulsed fibre lasers, high-speed scanning heads and optimised optics—have enabled cutting speeds exceeding several metres per second while maintaining kerf widths below tens of micrometres and limiting thermal damage. Rigorous control of parameters such as laser power, pulse duration and scanning speed allows manufacturers to tailor the heat-affected zone, mitigate spatter and preserve the integrity of active materials. These capabilities are essential to maintain electrical performance, reduce wastage and scale production for electric-vehicle and portable-electronics markets.
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Laser Cutting Techniques in Lithium-Ion Battery Manufacturing publication trend
The graph below shows the total number of articles in laser cutting techniques in lithium-ion battery manufacturing across all publications each year (not limited to Nature Index journals).
Technical terms
Current collector: Thin aluminium or copper foil providing the electrical pathway between electrode materials and external circuitry.
Kerf: The width of material removed by the laser cut, which influences edge precision and electrode fit.
Heat-affected zone (HAZ): Region adjacent to the cut where thermal exposure alters material microstructure or coating properties.
Continuous-wave (CW) laser: A laser that emits a steady, uninterrupted beam, offering consistent energy delivery for cutting applications.
Pulsed laser: A laser that emits energy in short bursts, allowing for controlled ablation and reduced thermal load per pulse.
References
- Characterization and process optimization of remote laser cutting of current collectors for battery electrode production. Journal of Materials Processing Technology (2024).
- Numerical and Experimental Study of High‐Speed Laser Cutting of Copper Current Collectors: Process Optimization for Quality Assessment. Advanced Materials Technologies (2025).
- The effect of process parameters on the high-speed cut quality of Li-ion electrodes using a single mode continuous fiber laser. Optics & Laser Technology (2025).
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