TRUMPF lasers weld door and window frames effectively, using less material and in an attractive design. Reinforcement plates are also optimally integrated using this technology. For this we offer our customers solutions that considerably reduce the number of process steps and process chains. TRUMPF lasers set welding spots and welding seams in every shape and direction. Narrower flanges on the doors save material, weight and costs.

To manufacture B-pillars that offer maximum safety and are at the same time considerably lighter than an exclusively steel construction, automobile manufacturers rely on a combination of steel, high-strength steels and plastics. For such hybrid connections, TRUMPF offers secure, local joining processes. With the laser it is no longer necessary to use any filler material for welding.

Lightweight construction in the automotive industry is based on many new materials, compounds and the use of aluminum. For all these materials and their processing, TRUMPF has ideal beam sources and the corresponding process know-how. Furthermore, our application engineers at the TRUMPF Laser Application Center always find the correct parameters for your specific application.

Hairpins are rectangular copper wires that are used in the grooves of the electrical plates of E-Drives and then welded at the front side. They replace round copper wires that were previously wound. TRUMPF lasers remove the insulating layer of paint in preparation for welding. The TRUMPF image processing VisionLine hereby ensures durably precise welds which are always located correctly. This provides you with highest quality combined with fastest throughput times and no reject parts.

Differentials in e-cars need to be increasingly lighter and at the same time more stable. The required material combinations made of cast-iron and case-hardened steel are difficult to join with conventional welding processes. However, the laser is the perfect tool for this purpose. Combined with extensive sensors it ensures welding seams in best quality. TRUMPF seam position control SeamLine Pro, for example, monitors the seams before, during and after the welding. The high-precision welds also contribute to a significant reduction in running noises of the differential gear.

Gearwheels, driveshafts and intermediate shafts of high-strength materials are installed to increase the wear resistance of the gears. After the welding has been completed TRUMPF marking lasers engrave the components with designations of origin and data for optimum traceability. The recess in the base material is extremely resistant due to the material coating and guarantees permanent readability.

The battery pack combines all battery modules and is welded to a compact block. Customers use TRUMPF lasers to weld the components and casing of the pack tightly and with high precision. The precision tool provides new solutions for the manufacture and integration of the cooling system. The quality of the welds is constantly monitored by intelligent sensors.

High quality cell connectors are decisive for the performance of the entire battery. TRUMPF lasers weld cell connectors of copper and aluminum as well as charged batteries safely, flexibly and with no contact. In the case of heat-sensitive workpieces, in particular, it is important to make high-strength welds with as little energy input as possible. With its innovative technologies such as oscillation welding (wobbling) or BrightLine Weld, TRUMPF opens the design capabilities for this.

In electric vehicles the plugs, connectors and contacts must be splash-water protected, clean and permanently connected. To achieve this TRUMPF provides solutions in the area of copper welding with green laser light that causes almost no spatter. The wobbling technique or new technologies, such as BrightLine Weld for IR Lasers are suited for low-resistance connections between the battery and the power electronics. The laser welding also enables durably sealed plastic and aluminum housings. Customers also use TruMark marking lasers for durable and fast identification for traceability.

In the manufacture of housings for sensors in electric vehicles, our customers use the numerous advantages of the laser for spot and seam welding. For example, the generation of precise welding spots. In addition the targeted energy input of the laser for least possible disturbance of the sensitive electronics inside the housing.