Demo Machine #13: High-Precision Battery Electrode Cutting – Crusader with IR Edge Laser
Battery electrodes need clean, precise cuts to ensure efficient energy transfer and long-term durability
Challenge
Manufacturers often struggle to cut thin aluminum foils without distortion. Conventional rotary die-cutting often causes edge defects, material deformation, and inconsistent cuts. This leads to reduced battery efficiency and increased scrap rates.
Solution
The Crusader® Converter with IR Edge Laser offers high-precision laser cutting for battery electrodes. This system uses infrared laser technology, specifically designed for cutting thin foils with unmatched accuracy.
Features:
- Unlike rotary die cutting, the IR laser creates smooth, burr-free edges, eliminating material tapering and deformation while improving yield and battery performance
- In-line lamination separator paper is laminated onto the electrode sheet, preparing it for stacking in the next stage of battery assembly
By combining high-precision laser cutting, material handling, and in-line lamination, this solution delivers superior edge quality, repeatable accuracy, and higher manufacturing efficiency.
Note: This material was coated in Demo 9. These demonstrations show
a seamless transition from coating to cutting in battery manufacturing.
Laser Die Cut Electrode
In this demo, the material coated in Demo 9 has been placed on our Crusader® Converter with an IR Laser. Which is then laser cut to and prepared for stacking.
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