GW Laser ABR Technology: Enabling New Energy, Cracking The Challenges Of Laser Processing Of Highly Anti-Reflective Materials

Materials Challenges and Opportunities in the New Energy Era

The new energy vehicle industry is leading the global green revolution with thunderous force. Its core components - battery electrodes, connectors, motor windings, etc. - are widely made of high-performance materials such as copper and aluminum. Copper reduces internal resistance and improves charging and discharging efficiency with its excellent conductivity; aluminum reduces weight and extends range while ensuring structural stability with its lightweight and high-strength characteristics. However, the “high reflectivity” of these materials has become the “Achilles heel” of laser processing.

Highly reflective materials often reflect more than 90% of the laser light, like building a “light shield” between the laser and the material. This not only leads to a large amount of wasted energy (reflected light), but also poses a serious threat to the core components of the laser equipment (optical fibers, optics), shortening the life of the laser and pushing up costs. The processing instability caused by reflected light directly leads to fatal defects such as poor welding and rough cutting, jeopardizing the performance and safety of new energy vehicles. Tackling the processing of highly reflective materials has become a bottleneck that the industry needs to break through.

Breaking the game: GW OptoWay ABR Anti-High-Resistance Technology
Four Levels of Intelligent Defense, Firm Shield to Strike
In the face of the severe challenge of highly reflective materials, GW OptoHub laser, relying on profound technological accumulation and continuous innovation, has independently developed Anti-Back-Reflection (ABR) anti-high-reflection technology, constructed an industry-leading four-level active defense system, and completely overcome the pain points of highly reflective material processing:

1. Output head “outpost”: rapid reflection interception in the laser output “throat” - the output head internal, implanted high-precision reflection detector. When the reflected light generated by welding pure aluminum just shows its head, the water-cooled stripping device is instantly activated, 90% of the returned light is captured on the spot, and at the same time triggers the intelligent protection mechanism to quickly cut off the risky optical path, avoiding damage to the fiber optic cables and cutting head.
2. Cluster “two lines of defense”: two-way pumping “layers of filtration” using the original two-way pumping structure, set up two-stage reflective stripping device at the front of the cluster. Welding power battery copper-nickel composite tape, for example, the reflected light after the first level of stripping energy attenuation 80%, the second level and then attenuate 90%, and ultimately only a small amount of residual energy, completely eliminating the core optical path hidden danger.
3. Red light indicator “exclusive shield”: precision alignment of the “safety lock” for welding for positioning the red light indicator, individually designed two-stage protection device. Even when facing the mirror-like smooth surface of the aluminum pole column, the red light system can work stably and effectively control the error to ensure that each weld is precise and accurate.
4. Multi-module “synergistic operation”: “anti-anti-backlash alliance” for high-power scenarios In the 10KW-class multi-module laser, each module is equipped with an independent anti-anti-backlash device. When welding the aluminum alloy of the power battery shell (such as 6-series aluminum), the multi-module works in concert, and the single module can withstand continuous reflection of light impact more than 100,000 times, and the stability is more than 5 times higher than that of the traditional equipment.

Practical Sharpness: ABR Technology Leads to New Heights of Highly Anti-material Processing

Laser cutting: the nemesis of copper alloys
Challenge: The market demand for cutting precision and speed of copper alloys such as brass and copper violet is increasing, and their highly reactive characteristics are a pain point in the industry.

GW Solution: ABR technology empowers a 12KW multimode laser to cut highly reactive copper alloys with ease.

Excellent performance:
4mm Copper (Oxygen Cutting): speed up to 10m/min.

4mm brass (nitrogen cutting): speeds up to 15m/min

Quality Assurance: The cutting surface is smooth and clean, no slag, no burr, win-win for both efficiency and quality.

Laser Welding: Power Battery Aluminum Alloy Welding Expert

Background: Aluminum alloy accounts for more than 90% of the materials used in power batteries, and the quality of its laser welding is crucial to the safety and performance of batteries.

GW Advantage: ABR technology combined with the exclusive 976nm high-brightness technology has significant advantages in the field of aluminum alloy welding.

Typical applications:
Positive pole/explosion-proof valve (Series 1 pure aluminum, <1mm): using GW 1KW single mode laser.

Green Empowerment: Sustainable Development Value of ABR Technology
Under the global green development wave, new energy vehicles shoulder the important responsibility of carbon reduction, GW Laser ABR technology not only solves the processing problems, but also contributes to the green value:

Energy saving and consumption reduction: Dramatically increase the utilization rate of laser energy, significantly reduce energy waste.

Low-carbon production: effectively reduce carbon emissions during processing.

Long-term environmental protection: equipment life extension, reduce equipment replacement frequency and waste generation.

Industry promotion: Provide key technical support for the efficient, high-quality and green manufacturing of core components for new energy vehicles, and help the industry to develop sustainably.

With its innovative four-stage protection system and excellent performance in the field, GW laser ABR anti-high-reflective material laser processing technology has successfully cracked the industry problem of high-reflective material laser processing, and provided a reliable, efficient, and green solution for the manufacturing of new energy vehicle power batteries and other core components. We continue to drive the green smart future with technological innovation.