The company's BLUE IMPACT series of direct blue diode lasers represents a significant leap forward in addressing one of manufacturing's most persistent challenges: efficiently welding highly reflective pure copper materials essential for EV batteries and motors.
Shimadzu's latest innovation delivers an unprecedented 6kW output power —quadruple the benchmark set by Japan's NEDO project in 2020. This remarkable power density enables single-pass welding of thick copper components that previously required multiple processing cycles, dramatically improving production efficiency.
In EV motor manufacturing, where stator winding connections demand exceptional precision, the system's high-power capability ensures consistent, high-quality welds that directly impact motor performance and longevity. Similarly, for battery production, the technology provides reliable solutions for tab welding—a critical process affecting both energy transfer efficiency and safety.
The BLUE IMPACT series introduces an industry-first "on-demand beam shaping" technology for blue lasers. By independently controlling six laser beams' power and positioning, the system concentrates intense energy at the weld center while surrounding it with lower-intensity beams. This innovative approach significantly reduces spatter—a common defect in copper welding that compromises quality and creates workplace hazards.
The adaptive control system dynamically adjusts beam profiles to match specific workpiece geometries, whether requiring deep-penetration welds with concentrated energy or broad surface welds with distributed heat input.
Unlike conventional circular beams that create uneven heat distribution, the system's rectangular fiber optic core (200μm × 400μm) ensures uniform energy dispersion across the entire weld area, enabling stable high-speed processing.
The 400-460nm blue laser wavelength demonstrates significantly higher absorption in copper compared to traditional infrared lasers—typically 5-10 times more efficient. This characteristic, combined with semiconductor lasers' rapid response and maintenance-free operation, makes the technology particularly suited for copper applications.
The 6kW system integrates six newly developed 1kW blue diode lasers through an advanced beam-combining optical head. Precise phase control maintains beam coherence during combination, while innovative cooling solutions ensure stable high-power operation.
Since 2016, Shimadzu has collaborated with Professor Masahiro Tsukamoto of Osaka University's Joining and Welding Research Institute on a NEDO-sponsored project to develop high-brightness laser processing technology. The partnership yielded the core beam-combining method that enables both high power and precision.
The company is currently working with a major machine tool manufacturer to commercialize the technology, with particular focus on EV component production including motors, battery modules, and power electronics.
This technological advancement arrives as global EV production faces increasing demands for reliable, high-throughput manufacturing of copper-intensive components. Industry analysts suggest the improved welding capability could help address production bottlenecks while enhancing product quality.
Beyond automotive applications, the technology shows promise for electronics manufacturing, medical devices, and aerospace components—all fields requiring precision joining of reflective materials.
Shimadzu, founded in 1875 and headquartered in Kyoto, maintains its commitment to developing analytical instruments, medical systems, and industrial equipment that support technological advancement across multiple sectors.