Problem
Client faced high rejection rates (18%) due to inconsistent spot welding on nickel strips for 18650 battery packs, leading to poor electrical connectivity and thermal issues.
Solution
Implemented precision laser welding with automated vision alignment and custom sandwich busbar design. Optimized weld parameters for uniform penetration depth.
Result
Rejection rate reduced to 2.5% within 3 months. Production output increased by 40% and battery pack resistance decreased by 22%.