The battery is one major cost driver and has an overall high-quality requirement on the joining technology. Therefore this novel holistic approach is a key process for electrification.


Each individual cell contact of a high-voltage battery module is measured using AI-supported image analysis to ensure a precise and reliable weld seam positioning. The basis for a stable and robust welding process is a broad fundamental knowledge and the use of research facilities such as DESY in Hamburg. This is the key to further improve the quality by looking into the invisible side of the process. To increase productivity and round off the holistic approach the use of the AI embedded sensor technology enables to obtain direct process feedback as a three-dimensional fingerprint of each individual weld seam. Using AI and extracting absolute physical values like static tensile force and welding depth enable a significant increase in data quality.


Through the quality control loop with batch size one scrap and high follow-up costs can be avoided. And finally, this plays an important role in reducing the CO2 footprint of the battery manufacturing.