2000W Air-Cooled Laser Welder for 2+6mm Battery Connector Welding

2026/9/23 - 2000W Air-Cooled Laser Welder for 2+6mm Battery Connector

On September 23, 2026, PDKJ carried out an on-site welding application for a new energy industry customer using a 2000W Air-Cooled Laser Welder. The application focused on laser welding 2+6mm battery connector joints — fusing a thin 2mm tab to a 6mm thick terminal block — at the customer’s facility, where penetration into the thick block without burning the thin tab, and controlled heat input overall are important for reliable production.

latest company case about 2026/9/23 - 2000W Air-Cooled Laser Welder for 2+6mm Battery Connector

The 2000W air-cooled laser welder stands beside the customer’s workbench as PDKJ and customer engineers prepare the battery connector welding application

Application Overview

Item	Details
Application	On-site laser welding of 2+6mm battery connector joints
Material	Aluminum battery connector — thin tab plus thick terminal block (exact alloy to be confirmed on site)
Joint Type	Dissimilar thickness: 2 mm tab welded to 6 mm block
Welding Process	Handheld fiber laser welding
Equipment	2000W Air-Cooled Laser Welder
Industry	New energy / battery manufacturing
Application Type	On-site welding application at the customer facility

Customer Welding Requirements

Battery connectors and busbar-style terminals often join two very different sections: a thin 2mm conductive tab that carries current from the cells, and a 6mm thick terminal block that forms the structural and electrical anchor. The joint between them must carry full current, resist vibration, and add as little resistance and weight as possible.

That 2+6mm combination is a classic dissimilar-thickness problem. Resistance welding needs very high force and current to penetrate the 6mm block — force that crushes and marks the 2mm tab. Conventional fusion welding dumps so much heat into the joint that the thin tab sags, the surrounding insulation suffers, and the connector distorts out of tolerance.

The customer therefore brought their own aluminum battery connectors to an on-site application with PDKJ: the goal was a full fusion into the thick block while the 2mm tab stayed intact, flat and bright.

The customer needed a welding solution that could provide:

Full fusion and penetration into the 6mm terminal block
No burn-through or sagging of the 2mm tab
Controlled heat input to protect the connector and nearby components
Clean, spatter-free connector surfaces ready for assembly
Repeatable joint quality across production batches
Handheld flexibility for different connector positions and fixtures
Weld parameters proven on the customer’s own connectors before production

A battery connector joint fails in the worst possible place: inside an energy storage system or battery pack. An under-penetrated weld into the 6mm block raises resistance and heats up under load; a burnt 2mm tab loses cross-section and cracks under vibration; and spatter on the connector surface can bridge insulation paths. Every rejected connector costs far more than the weld itself.

2000W Air-Cooled Laser Welding Solution for 2+6mm Battery Connectors

The 2000W air-cooled laser welder concentrates its beam into a small, intense spot that digs into the 6mm terminal block and fuses the 2mm tab to it in a single controlled pass. The key is asymmetry: the beam is aimed and shaped so that most of its energy lands on the thick block, which needs it, while the thin tab is heated only by the fused pool — enough to bond, never enough to burn.

Air cooling keeps the machine compact and mobile. In the application photos the welder stands beside the customer’s workbench as the PDKJ team and the customer’s engineers work through the connectors together, with no chiller, no plumbing and no dedicated welding bay required.

Parameters were tuned live on the customer’s own parts: power, travel speed and focus position were adjusted joint by joint until penetration into the block was complete, the 2mm tab kept its full profile, and the finished spots came out clean and bright with minimal spatter.

latest company case about 2026/9/23 - 2000W Air-Cooled Laser Welder for 2+6mm Battery Connector

Close-up of the aluminum battery connector showing the folded 2mm tab that must be fused onto the thick terminal block in the 2+6mm joint

How the Machine Solves Customer Pain Points 1. Full Penetration Into the 6mm Block

The 2000W source delivers the power density needed to fuse deep into the thick terminal, producing a joint that carries full current without hot spots or excess resistance.

2. The 2mm Tab Survives Intact

Heat input is steered into the thick section, so the thin tab stays flat and full-profile instead of sagging, burning back or losing cross-section at the joint.

3. Dissimilar-Thickness Joints Made Practical

Laser welding handles thickness ratios that defeat resistance welding, because force is zero and energy placement is geometric rather than brute-force.

4. Low Heat Input Protects Surrounding Components

The melted zone is confined to the joint. Nearby insulation, seals and electronics stay within safe temperatures, which matters inside finished battery assemblies.

5. Clean Surfaces Without Heavy Cleanup

A small, stable weld pool means minimal spatter. Connectors come off the bench ready for inspection and assembly instead of needing grinding or rework.

6. Parameters Proven on the Customer’s Own Connectors

Every setting used on site was validated on the actual 2+6mm aluminum connectors, so the results transfer directly into the customer’s production.

Welding Process

The welding process can generally be organized as:

Connector Cleaning and Fit-Up → Tab-to-Block Alignment → Parameter Setting for the 2+6mm Aluminum Joint → Tack Spot Welding → Full Joint Welding → Penetration and Surface Check → Batch Production Handover

Before production, welding parameters can be adjusted according to the material, workpiece structure, joint geometry, and required joint performance.

latest company case about 2026/9/23 - 2000W Air-Cooled Laser Welder for 2+6mm Battery Connector

The operator welds a battery connector joint on the workbench with the handheld laser torch while a customer engineer observes the process

Why Choose a 2000W Air-Cooled Laser Welder?

Dissimilar-thickness welding is a heat-management problem before it is a strength problem: the thick part demands energy that would destroy the thin one. Solving it needs a process that places energy precisely rather than spreading it.

The 2000W air-cooled laser welder provides that precision with the mobility of an air-cooled design, which is why it suits battery and new energy manufacturers running trials, small batches and varied connector geometries on the same machine.

This machine class suits battery connector and busbar welding, energy storage system assembly, motor and inverter connections, and general dissimilar-thickness joints. PDKJ builds a range of laser welding machines from portable air-cooled units such as the Portable Air-Cooled Laser Welding Machine to automated production systems.

Key Advantages

Full fusion into 6mm thick terminal blocks
Thin 2mm tabs welded without burn-through or sagging
Precise heat input for dissimilar-thickness joints
Minimal spatter — connectors ready for assembly
Air-cooled compact machine with no chiller required
Handheld torch adapts to varied connector positions
Fast single-pass joints on aluminum
Repeatable parameter sets for batch production
Simple operation with a short learning curve
Process validated on the customer’s own parts

Potential Applications

The same welding concept can be considered for various applications, including:

Battery connector and busbar terminal welding
Energy storage system interconnects
Battery pack tab-to-terminal joints
Motor, controller and inverter power connections
Dissimilar-thickness aluminum and copper joints
New energy vehicle electrical connections
Power distribution link welding
General 2–6mm mixed-thickness joint welding

Actual welding capability depends on the material, thickness, joint structure, electrode or fixture configuration, and production requirements.

From Customer-Site Testing to Production

The on-site application let the customer watch the welding process run on their own 2+6mm battery connectors, from the first parameter-setting tacks to fully welded sample joints.

Welds were inspected for penetration into the block, integrity of the thin tab and surface cleanliness, and sample joints were checked for mechanical strength.

Because the parameters were established on the customer’s own connectors, the settings proven on September 23 carry straight into the customer’s production.

Conclusion

The September 23 on-site application demonstrates the use of the 2000W Air-Cooled Laser Welder for welding 2+6mm battery connector joints, fusing a thin aluminum tab into a thick terminal block with controlled heat input.

For new energy manufacturers, laser welding turns dissimilar-thickness joints from a compromise into a controlled, repeatable process. PDKJ builds air-cooled and automated laser welding systems for battery and power connection applications, and a trial on your own connectors is the fastest way to confirm the process.

PDKJ continues to provide customized laser welding and resistance welding solutions based on different materials, workpiece structures, welding requirements, and production applications.