Open House

TECH-SONIC, Open House

for Ultrasonic Metal Welding Equipment for EV Battery Cell Level Applications

TECH-SONIC, will be hosting an Open House for ultrasonic welding equipment for EV battery cell level applications. The open house will be scheduled one week prior to the EV Battery Show and one week during the battery show. The given dates and hours are below. There will be refreshments and food provided.
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Location:
41650 Gardenbrook Rd.
Novi, MI. 48375
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Dates:
9/29/25-10/3/25 and
10/6/25 – 10/10/25

Hours:
9am-4pm EST

Host:
Michael Suttenberg

Contact Info:
Email: msuttenberg@techsonicultrasonic.com
Phone: (248) 241-7844

For those interested, please fill out a contact form of the interested application. The machines will demonstrate the solutions for current manufacturing problems in battery cell assembly, which include self alignment tooling and long tip welding for the 4680 battery. The machines that will be available at the open house for EV battery cell applications are:

Applications:

Register for the Open House

Tab-to-Tab Welding

In EV battery modules, multiple cells are connected in series and parallel to achieve the required voltage and current for the vehicle. This often involves welding the tabs of individual cells to a common busbar or to each other. TECH-SONIC’s ultrasonic welders, such as the US-3620SH Servo Spot Welder, are designed for this purpose.

Materials:
Ultrasonic welding is an ideal process for joining dissimilar metals, such as the copper and aluminum tabs often used in battery manufacturing. It creates a solid-state weld without melting the materials, which is crucial for maintaining the integrity of the cell.

The technology is used for:

  • Foil stack to tab welding: Attaching the multiple layers of foil to the collector tabs.
  • Tab-to-busbar welding: Connecting the tabs of multiple cells to a larger busbar to create a module.
  • Tab-to-tab welding: Directly joining the tabs of two or more cells.

Pouch Cell Welding

Pouch cells are a type of battery widely used in EVs due to their high energy density and flexible form factor. The manufacturing of pouch cells requires precise welding of the foil stacks and tabs, which are extremely thin and delicate.

Foil Stack Welding:
Pouch cells are made of many layers of ultrathin foils (anode and cathode). Welding these foils together requires a machine that can handle a large stack (e.g., up to 80 layers or more) without damaging the material. TECH-SONIC’s CLC technology is specifically designed to handle this, with the ability to detect single missing or added foils.

Tab Welding:
The tabs of a pouch cell are typically welded to the foil stack and then connected to the busbar. The self-leveling and multi-step welding processes in TECH-SONIC’s machines ensure that the delicate foils are not damaged and that the final weld is strong and reliable.

Preventing Defects:
The ability to measure start and end weld heights provides a critical quality control check. This helps manufacturers avoid internal short circuits by detecting and rejecting faulty welds before they can be sealed into the final pouch.

TECH-SONIC’s ultrasonic welding technology provides a reliable, precise, and efficient solution for the complex welding needs of modern EV battery production, particularly for critical processes like tab-to-tab and pouch cell welding.

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