At Hyperbat, our commitment to excellence in battery module welding is evident through our proven development and qualification processes. Our customers benefit from:
- Qualified weld solutions developed in weeks
- Parameters for ‘unweldable’ cell-to-busbar material combinations
- 99.7% weld success rate
- 150,000,000 welds on live cells across 5 distinct programmes
- Exceptional weld quality via adherence to BS EN ISO 3834-2
- Expansion to 3 laser welding systems in 2025, capable of welding all cell formats
Innovation: As pioneers in the UK, we have developed novel procedures for welding challenging material combinations, such as copper to aluminium and aluminium to steel, without significant formation of brittle Inter-Metallic Compounds. Our innovative approaches are adopted by customers in both the Automotive and Aerospace sectors.
Experience: With over 150 million Li-Ion battery welds on live cells, we have honed our expertise. Our quality assurance process includes the application of photo-electric diode sensors which monitor and record all process emissions to quantify weld quality. Based on experience, we have also created an empirical model to predict parameters for a wide range of applications to achieve optimum results, reducing development time and cost for our customers.
Qualification: Hyperbat adhere to BS EN ISO 3834-2 (Quality requirements for fusion welding – comprehensive) and all relevant ISO weld qualification, non-destructive and destructive testing standards, ensuring that best practice is in our DNA. Our rigorous weld qualification process is supported by our onsite, state-of-the-art metallurgy, metrology, and mechanical testing facilities in partnership with The Institute for Advanced Manufacturing and Engineering.
Fixturing and tooling: Our in-house designed and built laser welding tooling has been honed over the years. Where required, we incorporate process gas directly to each and every weld, minimising laser/plume interactions, enabling outstanding weld quality and penetration depth consistency.
Expert Team: Our laser welding engineers, with over 50 years of industrial experience, bring unparalleled knowledge and innovation to every project. They draw on experience from the nuclear, steel manufacture, aerospace, and automotive sectors where they have used every different type of high power materials processing laser. The team are specialists in electron beam welding as well as conventional welding techniques and have been recognised with prestigious awards, including the Royal Academy of Engineering Silver Medal and the Sir Henry Royce award for Technical Innovation.
Customer collaboration: We partner with our customers to embed manufacturing excellence across every battery development and series production programme. Our engagement typically starts with design-for-manufacture support and result in a repeatable, reliable, qualified process & quality battery product. Whatever the customer need or starting position, we are on hand to support.
Connect with us to learn more about our growing welding capabilities and discover how selecting Hyperbat as your manufacturing partner can help your business succeed.