Numerical and Experimental Study of High‐Speed Laser Cutting of Copper Current Collectors: Process Optimization for Quality Assessment

Ensuring high-edge quality in battery current collectors is crucial for improving battery performance and preventing potential safety issues. Defects such as uneven cuts, spatter, and excessive remelted zones can negatively impact the current collectors' electrical conductivity and mechanical integrity. Laser cutting offers advantages over mechanical methods by enabling faster processing, higher precision, and greater energy concentration. This study models and predicts defect occurrence under varying process parameters, focusing on the interaction between a single-mode continuous-wave (CW) laser and a copper current collector foil. Key factors influencing edge profile defects and cutting quality are investigated through experimental analysis and numerical simulation. A Computational Fluid Dynamics (CFD) model based on the volume of fluid method identifies parameters affecting the physical phenomena and optimal cutting conditions. Model validation is achieved by comparing experimental results across a range of process parameters associated with distinct defect formation modes. This model enables the prediction of defect types across a wide spectrum of laser speeds (2–25 m s−1), power levels (200–1000 W), and foil thicknesses (8–16 (Formula presented.)). Findings serve as a guideline for selecting process parameters when using current collectors of varying materials and thicknesses. © 2025 The Author(s). Advanced Materials Technologies published by Wiley-VCH GmbH.