Numerical modeling of high-speed laser cutting of copper current collectors

The increasing demand for lithium-ion batteries requires precise, efficient cutting of copper current collectors. Laser cutting offers advantages over mechanical methods in terms of speed, precision, and flexibility. This study uses validated multi-physics simulations to model the interaction between a single-mode continuous laser and 8 µm copper foils, analyzing how power, speed (up to 25 m/s), and foil thickness affect cut quality. Four outcomes were identified: no cut, dross, spatter, and clean cuts. Process maps for 8 µm and 16 µm foils were derived, offering insights for optimizing battery manufacturing.