Laser EMobility Workshop 2025

Innovative Hybrid Laser Welding Solution for Copper Hairpins Presented at Upcoming Conference

IMA EV-TECH, in collaboration with the Department of Mechanical Engineering at Politecnico di Milano, will present a pioneering approach to laser welding in electric motor manufacturing. The talk, titled "Development of a hybrid blue/NIR wavelength solution for laser welding of Cu hairpins", will be delivered by Giulio Borzoni on Wednesday, October 8th at 15:30.

The presentation outlines a novel hybrid beam configuration that combines a near-infrared (NIR) fiber laser with a blue diode laser. This dual-wavelength approach aims to suppress spatter formation during the welding of copper hairpins (critical components in stator assemblies) while preserving mechanical integrity. Traditional NIR-based welding methods, though widely adopted, face limitations in managing assembly tolerances and maintaining cleanliness within confined mechanical setups. The proposed solution addresses these challenges by leveraging wavelength-domain beam shaping.

The research spans from system conceptualization to proof of concept, offering insights into how wavelength selection can influence melt pool dynamics and weld quality. The hybrid configuration demonstrates improved process stability and reduced contamination, which are essential for high-volume electric motor production.

This development reflects a broader trend in industrial laser applications, where precision, cleanliness and adaptability are increasingly prioritized. As electrification accelerates across automotive and industrial sectors, innovations like this hybrid welding system could play a key role in enhancing manufacturing efficiency and product reliability.

The session will be of particular interest to professionals in laser processing, electric mobility, and advanced manufacturing technologies.