ACEY-CLW3000W Cantilever Laser Welder Lifts Battery Tab Welding Efficiency 40% for US Energy Storage Assembler

ACEY delivered a complete laser welding solution to a residential energy storage battery pack assembler in the United States. The customer needed to weld cell connector tabs and related conductive metal parts inside battery modules, working mainly with aluminum tabs and copper-aluminum composite tabs. A single ACEY-CLW3000W 3000W cantilever laser welding machine was selected, installed and commissioned within a 15-day project delivery window. The result: welding efficiency up by roughly 40% and a smoother hand-off to downstream assembly stations.

The customer's module assembly line handles a mixed, changing mix of workpieces. Aluminum connector tabs and copper-aluminum composite tabs differ in base material, sheet thickness and joint structure, so a single fixed welding recipe could not cover the full production range. The customer's requirements were clear:

• Process flexibility — one machine able to adapt to different material combinations, thicknesses and joint geometries without constant re-tooling.
• Consistent weld quality — repeatable, low-spatter joints on thin conductive tabs where overheating risks damage to nearby cells.
• Operational flexibility — an open, accessible working envelope so operators can load modules quickly and reposition the welding head over large pack formats.
• Production efficiency — shorter cycle time at the welding station to relieve the bottleneck feeding downstream assembly.

ACEY supplied one ACEY-CLW3000W 3000W cantilever laser welding machine. The cantilever design gives operators a wide, unobstructed working area, so battery modules can be positioned easily and the welding head moved directly over each joint. This is a practical advantage when pack formats vary and when tabs are located deep inside a module frame.

Two core features address the customer's mixed-material challenge directly:

• Three working modes — continuous, modulated and pulsed. Different material combinations and sheet thicknesses respond differently to heat input. Having three modes available lets the customer select an appropriate energy delivery profile for aluminum tabs, copper tabs and copper-aluminum composite tabs, rather than forcing every joint through one fixed setting.
• Constant-temperature water cooling system. Stable thermal management supports continuous production runs, protecting the optical path and keeping welding output consistent across a full shift instead of drifting as the machine heats up.

Within the machine's qualified process window, the CLW3000W welds aluminum strip, copper strip and copper-aluminum composite strip — covering the customer's complete tab range with a single asset.

By shortening the welding operation itself, the customer gained more than raw speed. The welding station stopped being the pacing constraint on the line, which gave production planning more room to schedule subsequent assembly steps and balance workload across the module build.

"We are very satisfied with the equipment configuration, the welding modes and the delivery service of the ACEY-CLW3000W cantilever laser welding machine. The machine is flexible to operate and meets our welding needs across different metal materials. The whole cooperation went smoothly, delivery was on time, and the result matched our purchasing expectations."

Battery pack manufacturing is unforgiving: tab joints must be electrically sound, mechanically reliable and produced at a rate that keeps a module line moving. Mixed materials make this harder, because aluminum and copper behave differently under a laser. A machine that offers selectable energy delivery modes, stable thermal control and an accessible working envelope gives assemblers room to tune each joint family instead of compromising on one setting for all of them. For this US customer, that flexibility translated into a 40% efficiency gain and a cleaner hand-off to downstream assembly.