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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Nanosecond Laser Cutting of Double-Coated Lithium Metal Anodes: Toward Scalable Electrode Manufacturing

by
Masoud M. Pour
1,*,
Lars O. Schmidt
2,*,
Blair E. Carlson
1,
Hakon Gruhn
2,
Günter Ambrosy
3,
Oliver Bocksrocker
3,
Vinayakraj Salvarrajan
3 and
Maja W. Kandula
2
1
General Motors Global R&D Center, 30470 Harley Earl Blvd, Warren, MI 48092, USA
2
Institute of Joining and Welding, TU Braunschweig, Langer Kamp 8, 38106 Braunschweig, Germany
3
TRUMPF Laser- und Systemtechnik SE, Johann-Maus-Straße 2, 71252 Ditzingen, Germany
*
Authors to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2025, 9(8), 275; https://doi.org/10.3390/jmmp9080275
Submission received: 8 July 2025 / Revised: 24 July 2025 / Accepted: 1 August 2025 / Published: 11 August 2025
Versions Notes

Abstract

The transition to high-energy-density lithium metal batteries (LMBs) is essential for advancing electric vehicle (EV) technologies beyond the limitations of conventional lithium-ion batteries. A key challenge in scaling LMB production is the precise, contamination-free separation of lithium metal (LiM) anodes, hindered by lithium’s strong adhesion to mechanical cutting tools. This study investigates high-speed, contactless laser cutting as a scalable alternative for shaping double-coated LiM anodes. The effects of pulse duration, pulse energy, repetition frequency, and scanning speed were systematically evaluated using a nanosecond pulsed laser system on 30 µm LiM foils laminated on both sides of an 8 µm copper current collector. A maximum single-pass cutting speed of 3.0 m/s was achieved at a line energy of 0.06667 J/mm, with successful kerf formation requiring both a minimum pulse energy (> 0.4 mJ) and peak power (> 2.4 kW). Cut edge analysis showed that shorter pulse durations (72 ns) significantly reduced kerf width, the heat-affected zone (HAZ), and bulge height, indicating a shift to vapor-dominated ablation, though with increased spatter due to recoil pressure. Optimal edge quality was achieved with moderate pulse durations (261–508 ns), balancing energy delivery and thermal control. These findings define critical laser parameter thresholds and process windows for the high-speed, high-fidelity cutting of double-coated LiM battery anodes, supporting the industrial adoption of nanosecond laser systems in scalable LMB electrode manufacturing.
Keywords: lithium metal anode; laser cutting; nanosecond pulses; lithium metal battery production lithium metal anode; laser cutting; nanosecond pulses; lithium metal battery production

Share and Cite

MDPI and ACS Style

Pour, M.M.; Schmidt, L.O.; Carlson, B.E.; Gruhn, H.; Ambrosy, G.; Bocksrocker, O.; Salvarrajan, V.; Kandula, M.W. Nanosecond Laser Cutting of Double-Coated Lithium Metal Anodes: Toward Scalable Electrode Manufacturing. J. Manuf. Mater. Process. 2025, 9, 275. https://doi.org/10.3390/jmmp9080275

AMA Style

Pour MM, Schmidt LO, Carlson BE, Gruhn H, Ambrosy G, Bocksrocker O, Salvarrajan V, Kandula MW. Nanosecond Laser Cutting of Double-Coated Lithium Metal Anodes: Toward Scalable Electrode Manufacturing. Journal of Manufacturing and Materials Processing. 2025; 9(8):275. https://doi.org/10.3390/jmmp9080275

Chicago/Turabian Style

Pour, Masoud M., Lars O. Schmidt, Blair E. Carlson, Hakon Gruhn, Günter Ambrosy, Oliver Bocksrocker, Vinayakraj Salvarrajan, and Maja W. Kandula. 2025. "Nanosecond Laser Cutting of Double-Coated Lithium Metal Anodes: Toward Scalable Electrode Manufacturing" Journal of Manufacturing and Materials Processing 9, no. 8: 275. https://doi.org/10.3390/jmmp9080275

APA Style

Pour, M. M., Schmidt, L. O., Carlson, B. E., Gruhn, H., Ambrosy, G., Bocksrocker, O., Salvarrajan, V., & Kandula, M. W. (2025). Nanosecond Laser Cutting of Double-Coated Lithium Metal Anodes: Toward Scalable Electrode Manufacturing. Journal of Manufacturing and Materials Processing, 9(8), 275. https://doi.org/10.3390/jmmp9080275

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