In battery manufacturing, even small improvements in component quality and waste reduction can make a big difference in cost and efficiency. One common challenge many battery manufactures face is high scrap rates on ultra-thin battery tabs, the connectors critical for reliable electrical performance.
At Datum, we recently worked with a battery manufacturer struggling with scrap rates that were slowing their production and driving up costs. Using our ultra-thin laser cutting capabilities, we helped them reduce scrap by 30%, enabling faster, cleaner production runs.
Why Battery Tabs Are Tricky to Cut
Battery tabs are often made from very thin metal foils, sometimes as thin as 0.05mm. Cutting these ultra-thin materials accurately is tricky. Traditional mechanical cutting methods can cause burrs, deform the material, or create uneven edges. This can lead to poor welds, electrical resistance issues, and ultimately, higher scrap rates.
How Ultra-Thin Laser Cutting Makes a Difference
Our laser cutting technology provides a clean, precise cut with minimal heat-affected zones and no mechanical stress on the metal. This means edges are smooth and exact, reducing the chances of defects in the final battery assembly.
A major factor in reducing scrap is that we cut directly from coil, which is ideal for large production runs. Cutting from coil helps in two important ways:
- Less wasted material – the coil format for large production runs allows for continuous cutting with minimal off-cuts, reducing scrap right from the start.
- Fewer burrs and edge defects – the coil-fed material stays steady and stable during cutting, preventing movement that typically causes burrs and uneven edges.
Together, these benefits ensure tighter tolerances and consistently high-quality parts that improve your assembly process.
The Results
- 30% reduction in scrap thanks to cleaner cuts and more consistent tabs
- Improved assembly speed with parts that fit better and require less post-processing
- Lower material waste – a big win in both cost savings and sustainability
What This Means for Battery Manufacturers
If you’re facing similar challenges with battery tab quality or scrap rates, partnering with a specialist laser cutting provider like Datum can be a game-changer. We combine the right technology, materials expertise, and design support to help battery makers improve yield and speed up production.
Ready to Reduce Your Scrap Rates?
If you want to explore how ultra-thin laser cutting can benefit your battery manufacturing process, get in touch with us for a consultation or to submit your drawings for a quote.
At Datum, we’re a specialist development partner of battery cell connectors for battery pack manufacturers, from prototype through to full-scale production.