The two main production options available are continuous flow in-line or offline systems. It should be noted that the manufacturing flow can have an impact on the welding technology selected and this should be factored in at the technology selection stage. A consideration of materials, joint geometry, weld access, cycle time and budget will normally point in the direction of the required joining technology.

Production volume driven by consumer demand — The production volume of batteries continues to be driven by the demands of consumer electronics and electric vehicles. Likewise, the manufacturing and joining needs of these batteries are also pushed by capacity, size, materials and usage. Resistance, microTIG and laser technologies each have specific features that align well to these joining needs. A clear understanding of the technologies and application is needed to implement an efficient and reliable production welding system. The tables below offer some guidelines on the available methods and a few parameters including suitability for a variety of applications.

Geoff Shannon, Ph.D. is the laser technology manager for Miyachi Unitek Corp., which manufactures equipment and systems for resistance welding, laser welding, laser marking, laser cutting, and hot bar reflow soldering and bonding. Contact him at