E-MOBILITY


Ultrasonic welding


provides a promising link between sustainability


and cost-effectiveness in the production of EVs


ULTRASONICS UNDERSTANDING


Increasing the sustainability of EVs with ultrasonics to save energy, materials and rejects


T


he production of vehicles with internal combustion engines (ICEs) has undergone extensive optimisation over


the years, while the mass production of EVs is still in its early stages. This presents captivating opportunities for companies to enhance both production sustainability and cost-effectiveness. One promising solution is the use of ultrasonic welding technology. When joining both plastic and metal


26 www.engineerlive.com


applications, the process saves energy, scrap and raw materials, offering a promising link between sustainability and cost-effectiveness in the production of EVs.


SAVING ENERGY WITH ULTRASONICS One of the most significant opportunities for energy savings lies in battery production. Traditionally, the sealing of pouch cells has been


inefficient, often relying on thermal joining methods like heat sealing. However, these processes consume substantial amounts of energy and pose a risk of damaging the battery cell foils. Based on experience from other


industries, there is untapped potential here. Although ultrasonic sealing of pouch cells has not yet widely been implemented, it has successfully been used for sealing pouch packages in


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