Application and technical advantages of 3D laser cutting in new energy vehicle manufacturing

3D laser cutting technology is widely used in the new energy vehicle (NEV) industry, primarily for high-precision processing of complex metal components. This technology utilizes high-energy laser beams to achieve rapid material cutting and is suitable for various metals, including aluminum alloys, high-strength steel, and copper alloys.
In battery manufacturing, 3D laser cutting is applied to process battery trays, enclosures, and conductive connectors. Battery trays require precise cutting of cooling holes, mounting holes, and edge contours, where laser cutting ensures smooth edges, eliminates burrs, and maintains sealing integrity. Conductive connectors demand extreme cutting accuracy, and laser technology minimizes thermal distortion while preserving electrical conductivity.
For vehicle body production, 3D laser cutting is ideal for processing aluminum-steel hybrid materials. To reduce weight, NEVs often use aluminum alloy or hot-formed steel components such as crash beams and A/B pillars. Unlike traditional stamping, which requires custom molds, laser cutting directly follows 3D models, adapting to complex curvatures and shortening production lead times.
Motor and electronic control system housings, end covers, and other components also require high-precision hole cutting and edge trimming. Laser cutting effectively handles intricate features like cooling channels and mounting holes on complex surfaces, ensuring assembly accuracy and thermal management. Additionally, small metal parts such as seat frames and charging port brackets can be rapidly formed via laser cutting to accommodate design variations across vehicle models.
The key advantages of 3D laser cutting include high precision (±0.1mm), flexibility, and efficiency. Compared to conventional machining, it eliminates the need for molds, making it ideal for low-volume customized production. The technology also integrates seamlessly with automation systems, working alongside robotic arms or 5-axis machines to achieve precise cuts on complex spatial curves.
Current challenges include improving process stability for highly reflective materials like copper and aluminum. Some manufacturers address this by adopting higher-power fiber lasers or blue laser technology. Moving forward, advancements in smart manufacturing will further enhance automation, integrating real-time inspection and adaptive processing systems to boost efficiency and quality in NEV production.