Classification of defects and acceptance levels for increased
electrical safety in laser welded aluminum busbars

CODELAB is a collaborative research project funded by Vinnova and coordinated by Swerim, running from August 2025 to August 2027. Together with partners Scania, Volvo AB, Lasertech, and Svetskommissionen, we aim to improve electrical safety, battery durability, and fire protection in laser welded aluminum busbars.

About the project

Laser welding is increasingly used in battery module manufacturing, especially for aluminum busbars that carry high currents. However, the lack of standardized guidelines for defect classification and acceptance levels leads to:

• Inconsistent testing
• Reduced electrical performance
• Increased safety risks
• Higher scrap rates and costs

Project goals

• Develop industry-wide guidelines for defect classification and acceptance levels
• Support international standardization efforts
• Promote skills development through seminars, training, and publications

Why your input matters

The industry currently lacks unified standards for laser welded current-carrying welds in battery modules. We are looking for input from companies, researchers, and regulators to help us:

• Identify common defect types and how they are currently detected and measured
• Understand what problems these defects cause in real-world applications
• Learn about your existing QA systems and acceptance criteria
• Define practical and realistic acceptance limits
  

Whether you work in manufacturing, quality assurance, R&D, or regulation, your insights can help shape safer and more efficient battery systems.

Submit your input

We welcome your suggestions, questions, or data contributions. Please fill out the form below. Your input will be sent to Svetskommissionen's project representative as well as the CODELAB coordinator team at Swerim.