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TRUMPF copper welding application example

Welding copper - one application, a few challenges

Components made of copper play a key role in many sectors: whether it's e-mobility, electronics or in the jewelry and watchmaking industry. There are two main challenges when welding the highly reflective material: weld seams with consistently high weld quality and minimal spatter. This is where the laser comes into its own. High-strength connections which are also entirely reproducible and have high conductivity can be achieved with non-contact tools. And in comparison with TIG welding, no additional material is required which would make the component heavier.

Copper welding - stable and practically spatter-free

What different methods can be used to weld copper?

TIG welding, soldering, screwing - what are the advantages of copper welding with a laser in comparison with alternative methods?


Compared to TIG welding, screwing or soldering, this laser can produce consistent weld seams without additional material.

High quality

Copper welding with a laser inhibits the formation of pores thanks to optimized weld pool dynamics. Spatter is effectively reduced.


Regardless of the material surface composition, the green laser produces weld seams of a consistently high quality.


Welding copper and aluminum connections is possible with minimal mixing of materials (intermetallic phase), resulting in a high degree of stability and conductivity.


A laser is a non-contact tool with no wear. Components are not contaminated or damaged.

Application examples

TruLaser Station 7000 laser welding automotive application

Copper connections for power electronics

The increasingly compact housings and the higher performance required for electronic components are also increasing the requirements for the joining technology used with copper components. Pulsed green lasers weld these materials with a high level of reproducibility and with almost no spatter - regardless of the surface properties.

TRUMPF copper welding application cell connector

Joining of dissimilar materials for cell contacts (busbars)

Lasers are ideally suited to sensitive battery cells as they complete their task without any contact and require little energy. The material is not mechanically stressed. The locally limited, low heat input ensures high-precision distortion-free seams.

Manufacturing of battery cells with TRUMPF lasers

Welding battery housings and cell connectors

Using TRUMPF lasers, customers can weld battery housings and cell connectors made from copper and aluminum effortlessly and with precise seams. In this manner, increasingly small and powerful cells can be integrated into a battery array. A comprehensive system of sensors monitors the quality of the weld seams and ensures precise welding depths here.

TRUMPF copper welding hairpin

Hairpin welding for electric motors

Short pulse lasers are used in hairpin welding to remove the layer of insulating varnish without damaging the underlying copper. Thanks to the high level of reproducibility of laser welding processes, users achieve consistently high-tensile connections with a good level of conductivity - and this in high quantities for series production!

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