SFL Series Fiber Laser Welding Cell

Production-ready fiber laser welding for battery modules, tabs, busbars, and high-current interconnect assemblies.

The Sunstone® SFL Series Fiber Laser Welding Cell is a configured, enclosed fiber laser welding platform built for battery manufacturing environments where precision, repeatability, throughput, and support matter. Available in 1,500 W and 3,000 W configurations, the SFL Series combines industrial fiber laser power with integrated motion control, 2-axis galvo scanning, X-axis linear motion, water cooling, and a fully enclosed work cell.

For battery manufacturers producing EV battery packs, energy storage systems, aerospace batteries, UAV batteries, or industrial power systems, the SFL Series provides a practical path to automated battery welding without starting from a custom automation project from scratch.

Core Platform Specifications

Platform Feature	SFL 1500	SFL 3000
Laser Source	1500W Fiber	3000W Fiber
Wavelength	1070 nm, ±10 nm	1070 nm, ±10 nm
Working Mode	Continuous / Modulation	Continuous / Modulation
Motion System	X-Axis Linear + 2-Axis Galvo	X-Axis Linear + 2-Axis Galvo
Working Area	1000 × 800 mm	1000 × 800 mm
Safety Enclosure	Fully enclosed work cell	Fully enclosed work cell
Functions	Weld / Clean / Cut	Weld / Clean / Cut

SFL 1500 vs. SFL 3000

The SFL Series is available in two configurations. Both systems share the same enclosed work cell platform, 1070 nm fiber laser wavelength, X-axis linear motion, 2-axis galvo scanning, 1000 × 800 mm working area, water cooling, and weld / clean / cut capability. The right configuration depends on your material stack, joint design, throughput requirements, and production goals.

SFL 1500

1,500 W Fiber Laser

Best suited for pilot production, battery development programs, moderate-volume manufacturing, tab welding, and module assembly.

SFL 3000

3,000 W Fiber Laser

Best suited for high-volume manufacturing, larger battery modules, copper busbar welding, demanding production environments, and maximum throughput requirements.

Evaluating fiber laser welding for battery production?

Talk with Sunstone® about your cell type, tab design, busbar geometry, material stack, site requirements, and production goals.

Talk to an Application Engineer

Request a quote · Send sample parts

Site Readiness and Installation Requirements

The SFL Series is built as an integrated welding cell, but successful deployment still depends on preparing the production site correctly. Sunstone® helps customers review facility requirements, cooling needs, electrical service, shielding gas, compressed air, and application-specific configuration before implementation.

Requirement	SFL 1500	SFL 3000
Input Power	480V, 3-Phase, 60 Hz	480V, 3-Phase, 60 Hz
Operating Voltage, Internal	220V ±40V	220V ±40V
Total Power Consumption	~7.5 kW	Confirm with factory
Recommended Capacity	15–20 kVA	30–40 kVA
Recommended MCB/MCCB	32A minimum / 40A preferred	32A minimum / 40A preferred
Cooling Method	Water cooling, DI	Water cooling, DI
DI Water Required	16 L minimum	16 L minimum
Max Cooling Pressure	1.0 MPa	1.0 MPa
Operating Temperature	10–40°C	10–40°C
Max Humidity	<70% non-condensing	<70% non-condensing
Required Utilities	Shielding gas, N2 or argon, and compressed air	Shielding gas, N2 or argon, and compressed air

All specifications are subject to change. 3000W power consumption should be confirmed with the factory. Shielding gas, N2 or argon, and compressed air are required for operation.

Safety and Compliance

Fiber laser welding gives manufacturers a powerful production tool, but safety and compliance matter when adding a laser process to the factory floor. The SFL Series uses a fully enclosed, interlocked work cell designed to support safer operation in production environments.

Built for industrial laser safety planning

The SFL Series features a fully enclosed Class 1 work cell and an FDA 21 CFR 1040.10 (CDRH) compliant enclosure. This helps de-risk implementation for manufacturers evaluating an enclosed fiber laser welding system for battery module production.

What the SFL Series Is Designed to Weld

The SFL Series is engineered for the materials and connection types commonly found in today’s battery systems. Compatible materials include copper, nickel, aluminum, steel, stainless steel, carbon steel, nickel-plated copper, copper clad, clad battery tabs, titanium, and dissimilar-metal combinations.

Typical battery applications include cylindrical cell modules such as 18650 and 21700 formats, prismatic cell modules, battery tab welding, copper tab welding, nickel-plated copper tab welding, busbar-to-terminal welding, cell-to-busbar welding, battery module assembly, battery pack manufacturing, energy storage system production, aerospace battery manufacturing, and UAV battery production.

The ability to weld copper and dissimilar-metal combinations is especially important as manufacturers move toward higher-current battery architectures designed to improve electrical performance.

Common SFL Series Capabilities

Battery Module Assembly

Cylindrical cell modules, prismatic cell assemblies, busbar-to-terminal connections, cell housing seam welds, and ESS module production.

Multi-Material Joining

Copper to copper, nickel to nickel, nickel-plated copper tabs, copper-clad battery tabs, and dissimilar metal combinations.

Production Flexibility

Laser welding, laser surface cleaning, laser cutting, and custom weld pattern programming in one enclosed work cell.

Why Battery Manufacturers Choose Fiber Laser Welding

As battery technologies evolve, manufacturers are working with more challenging material combinations, higher current requirements, and more complex interconnect designs. Fiber laser welding offers a precise, automation-ready process for these demands.

Because fiber laser welding delivers concentrated energy directly where it is needed, it can help minimize thermal impact on surrounding materials. That matters in battery production because cells and interconnects can be sensitive to excessive heat exposure.

Laser welding is also a non-contact process. Unlike electrode-based welding methods, the laser does not physically contact the workpiece. This eliminates electrode wear, reduces maintenance related to electrode contact, and helps protect delicate battery components from mechanical stress.

For production environments, speed and consistency are critical. Battery packs may require hundreds or thousands of welds per assembly, so the welding process must support automated throughput without sacrificing repeatability. Fiber laser welding integrates naturally into automated manufacturing environments, supporting scalable production from pilot programs to full-scale manufacturing.

Two blue cylindrical battery cells with welded connections on top — Example cylindrical battery cell welding showing welded connections on the top of the cells.

Built for Production Battery Welding

The SFL Series combines a fully enclosed work cell with advanced motion control to support efficient production workflows. A large 1000 × 800 mm working area accommodates battery modules, fixtures, and production assemblies of varying sizes.

The system integrates X-axis linear motion with 2-axis galvo scanning, allowing high-speed pattern welding across large work areas while maintaining precise laser positioning. Continuous and modulation operating modes allow manufacturers to optimize welding parameters for different materials, thicknesses, and battery designs.

The enclosed welding environment supports safe operation while helping protect the process from external influences that can affect weld consistency. This production-ready design reduces the complexity of sourcing a laser, enclosure, motion platform, programming workflow, and support separately.

A Faster Path to Battery Production

Many battery welding systems fall into one of two categories: low-cost imports that may create support and implementation concerns, or high-end OEM systems that may require longer deployment timelines and larger capital investment.

The SFL Series is positioned between those extremes. It gives manufacturers a fully integrated fiber laser welding cell with practical deployment, industrial capability, and U.S.-based support.

For teams that need to move quickly, the SFL Series provides a faster, lower-risk path to battery welding capability compared with building a custom system from scratch.

Cylindrical battery cells welded into paired connections for battery module assembly — Example battery module welding with cylindrical cells joined in paired connections.

Need to validate your battery welding application?

Talk with Sunstone® about your materials, tab design, busbar geometry, site readiness, production goals, and weld quality requirements.

Talk to an Application Engineer

Request a quote · Send sample parts

Weld, Clean, and Cut in One Enclosed Work Cell

The SFL Series supports welding, laser surface cleaning, and laser cutting operations in one enclosed work cell. For manufacturers working with battery modules or metal assemblies, this 3-in-1 capability can support multiple process needs within one enclosed platform.

The system is also designed for custom weld pattern programming, making it adaptable to different part geometries, battery module layouts, and production requirements.

Why Choose Sunstone®?

Successful battery welding requires more than laser power. Material behavior, fixturing, motion control, process development, and weld validation all contribute to manufacturing success.

Sunstone® works directly with customers to evaluate applications, develop welding processes, test materials, optimize production parameters, and scale from prototype to production. Our application engineering team helps manufacturers identify the best welding strategy for their specific battery design, material stack, and production goals.

Production-Ready Cell

A fully integrated welding cell designed to reduce the need for a custom integration project.

U.S.-Based Support

Engineering and service support from Spanish Fork, Utah.

Rapid Deployment

A practical path to production battery welding capability without building a custom system from scratch.

Application-Specific Configuration

Configured around your cell type, tabs, busbar geometry, material stack, and production requirements.

Additional Precision Laser Applications

The SFL Series is battery-first by design, but the enclosed fiber laser platform can also support select precision welding and processing applications beyond EV and energy storage battery production.

Potential applications include aerospace assemblies, medical device components, electronic interconnects, sensor manufacturing, precision metal fabrication, research and development applications, and advanced manufacturing programs. These should be evaluated based on the material, part geometry, production requirements, and process goals.

Not Sure If the SFL Series Is Right for Your Battery Welding Application?

Battery welding requirements vary by material, cell type, tab design, busbar geometry, and production volume. The right system depends on the joint, part design, materials, fixture strategy, and weld quality requirements.

If you are evaluating fiber laser welding for battery modules, cell assemblies, copper tabs, nickel tabs, busbar connections, or multi-material joining, Sunstone® can help review your application and recommend the best configuration.

Frequently Asked Questions About the SFL Series

What is the SFL Series?

The SFL Series is a fully integrated fiber laser welding cell designed for EV battery module production, high-current battery assemblies, multi-material joining, and general metal fabrication.

What battery applications is the SFL Series designed for?

The SFL Series is designed for cylindrical cell modules, including 18650 and 21700 assemblies, prismatic cell assemblies, battery tab welding, copper tab welding, nickel-plated copper tab welding, busbar-to-terminal welding, cell-to-busbar welding, ESS module production, aerospace battery manufacturing, UAV battery production, and battery pack manufacturing.

What materials can the SFL Series weld?

Compatible materials include copper, nickel, aluminum, steel, stainless steel, carbon steel, nickel-plated copper, copper clad, clad battery tabs, titanium, and dissimilar-metal combinations.

What is the difference between the SFL 1500 and SFL 3000?

The SFL 1500 provides 1500 watts of fiber laser power and is well suited for pilot production, battery development programs, moderate-volume manufacturing, tab welding, and module assembly. The SFL 3000 provides 3000 watts of fiber laser power for high-volume manufacturing, large battery modules, copper busbar welding, demanding production environments, and maximum throughput requirements.

Is the SFL Series only for EV battery welding?

No. The SFL Series is optimized for battery manufacturing, but it can also support select aerospace assemblies, medical device components, electronic interconnects, sensor manufacturing, precision metal fabrication, research and development applications, and advanced manufacturing programs.

Is the SFL Series production-ready?

Yes. The SFL Series is designed as a production-ready, fully integrated welding cell. It is built to reduce the complexity of sourcing the laser, enclosure, motion platform, programming workflow, and support separately.

Does the SFL Series require shielding gas or compressed air?

Yes. Shielding gas, either N2 or argon, and compressed air are required for operation.

What support does Sunstone® provide?

Sunstone® provides U.S.-based engineering and service support from Spanish Fork, Utah, along with application evaluation, process development, material testing, production parameter optimization, and support for scaling from prototype to production.

Ready to Discuss Your Application?

Whether you are developing a next-generation battery architecture or scaling an existing production line, the Sunstone® SFL Series Fiber Laser Welding Cell provides the precision, flexibility, and automation capabilities needed for modern battery manufacturing.

Talk with Sunstone® about your battery welding application.

Review your materials, cell type, tab design, busbar geometry, production goals, facility requirements, and weld quality expectations with an application engineer.

Talk to an Application Engineer

Request a quote · Send sample parts

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