Numerical modeling of high-speed laser cutting of copper current collectors
Samuele Piandoro, Caterina Angeloni, Alessandro Fortunato, Erica Liverani, Alessandro Ascari
Abstract. 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.
Keywords
Laser Cutting, Copper, Multi-Physics Simulation, Process Optimization
Published online 9/10/2025, 8 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Samuele Piandoro, Caterina Angeloni, Alessandro Fortunato, Erica Liverani, Alessandro Ascari, Numerical modeling of high-speed laser cutting of copper current collectors, Materials Research Proceedings, Vol. 57, pp 319-326, 2025
DOI: https://doi.org/10.21741/9781644903735-37
The article was published as article 37 of the book Italian Manufacturing Association Conference
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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