future of welding in lithium-ion battery manufacturing

The Future of Welding in Lithium-Ion Battery Manufacturing


Meet Stefan Pfanner - our International Welding Expert.

Stefan gave an interview with a focus on advancing the processes crucial to lithium-ion battery manufacturing. Let’s explore Stefan’s insights and endeavors shaping the future if welding in lithium-ion battery manufacturing.


Stefan Pfanner, expert in the field of welding and the future of welding in lithium-ion battery manufacturing

What exactly makes the welding process so demanding in lithium-ion battery manufacturing?

Stefan: Welding, especially in the context of lithium-ion battery manufacturing, is in itself a “special process.” The inner quality condition of the seam is challenging to detect non-destructively, demanding special attention, care, and knowledge.

Modern equipment has significantly supported our ability to meet high-quality requirements, but the complexity arises from the multitude of possible parameter settings. Reaching the right combination is a special challenge for end-users.

What are you currently working on?

Stefan: My current projects are multi-faceted. I’m deeply involved in the development and evaluation of process- and welding-parameters, especially for materials that pose inherent challenges in joining. Customer-focused optimization of welding process parameters, including all relevant pre- and post-process steps, is a continual focus to ensure tailored solutions.

I also provide technical expertise and customer support when welding issues arise, emphasizing a proactive approach. Integration of (online) process surveillance systems is an ongoing effort, coupled with strategies to effectively manage the substantial amount of data generated.

Achieving an efficient and cost-effective welding process with the largest possible stable process window, tailored to customer needs, is a pivotal part of my current pursuits. Lastly, guiding customers in selecting the right equipment for specific welding tasks is an integral aspect of my role.


What are your visions on the future?

Stefan: In envisioning the future of welding in lithium-ion battery manufacturing, my focus spins around four key aspects. First, ensuring a consistent integration of (non-destructive) process surveillance equipment to meet and exceed the highest quality demands on the customer side. This is already in progress, with varying levels of implementation based on the size of the manufacturer.

Secondly, I see immense potential in leveraging current technological developments and trends in laser technology. This includes adopting new laser beam forming and beam shaping technologies to join dissimilar materials and enhance seam quality, striving for spatter-free outcomes.

Thirdly, my vision involves the possibility for easy rework in case of welding defects occurring (beside the fact, that the process itself should be stable in origin with a process capability higher than 1,33/1.67)

Additionally, I see the search of more standardized products at both individual and assembly part levels. This not only streamlines the manufacturing process but also enhances efficient joining possibilities.

Thank you, Stefan, for joining the conversation on the future of welding in lithium-ion battery manufacturing!

BM Rosendahl battery prouduction laboratory


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