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2024 | OriginalPaper | Chapter

Challenges and Opportunities for Laser Applications in Electric Vehicle Manufacturing

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

Published in: Selected Topics in Manufacturing

Publisher: Springer Nature Switzerland

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Abstract

The chapter delves into the pivotal role of laser technology in the transition to electric vehicles (EVs), addressing the manufacturing challenges posed by the increasing demand for EVs. It discusses the advantages of laser-based manufacturing processes, such as welding, cutting, and structuring, in the production of key EV components like battery systems, powertrains, and hairpin windings. The text also highlights the need for collaboration between industry and academia to advance the knowledge base and meet sustainability goals in electric vehicle manufacturing.

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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.

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Title: Challenges and Opportunities for Laser Applications in Electric Vehicle Manufacturing
Authors: Ali Gökhan Demir
Johannes Kriegler
Alessandro Fortunato
Leonardo Caprio
Christian Geiger
Lucas Hille
Michael Karl Kick
Alessandro Ascari
Erica Liverani
Michael F. Zaeh
Publisher: Springer Nature Switzerland
Book: Selected Topics in Manufacturing
Print ISBN: 978-3-031-41162-5

Electronic ISBN: 978-3-031-41163-2

Copyright Year: 2024
DOI: https://doi.org/10.1007/978-3-031-41163-2_12

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