10122615Soni-Shape-Laser. Autogenous laser welding of aluminium battery cases, via contactless ultrasonic and free-form beam shaping.ActiveCollaborative R&DInnovate UKOne of the major hurdles in Electric Vehicle (EV) adoption is the **high cost**, partly from the **lack of flexibility/reconfigurability in battery pack production**. To tackle this, **Soni-Shape-Laser** **aims to offer an optimised commercial solution with a novel approach to laser welding 6xxx aluminium, commonly used in battery casings**. We're committed to advancing the UK supply chain and existing technologies for customised battery packs through flexible manufacturing. A vital component is the casing, designed for robust integration and safety in crash protection and thermal events. Supported by this grant, our laser welding technology aims to promote **flexibility/fast reconfigurability in battery pack production,** achieving efficient manufacturability, and a viable modular/scalable pack design. To address challenges associated to limited manufacturing flexibility/reconfigurability, Soni-Shape-Laser incorporates advanced technologies such as Power-Ultrasonic Vibration Treatment (PUVT) and free-form beam shaping. Useful for working with 6xxx aluminium alloys, known for high crack sensitivity, the integration of these technologies set a new industry benchmark and transition from wire-fed to a fully remote and autogenous (no wire) laser welding for hermetically sealed joining of battery casings. Soni-Shape-Laser will demonstrate at least a 20% increase in productivity, 50% fast changeovers with enhanced flexibility/reconfigurability, improved access to confined welding areas, 15% weight saving enabled by more intense use of aluminium, and 20% energy/cost saving and reduced emissions. Leveraging the consortium's deep expertise and proven success in relevant projects such as UltraMAT, Soni-Laser, LIBERATE and ALIVE, Soni-Shape-Laser is uniquely positioned to commercialise this cutting-edge technology. It aims to play a pivotal role in the global transition to electric mobility and carbon emission reduction. Soni-Shape-Laser is committed to fostering **social impact through job retention/future creation, skillset development and facilitating specialised training programs, to upskill the workforce,** paving the way for broader, sustainable industry adoption of these advanced technologies.