Lithium metal as an anode in the solid-state battery is a promising alternative to the intercalation type of anode in the lithium-ion battery. However, cutting of this component mechanically is challenging due to its high surface adhesion, chemical reactivity, and low rigidity. On the other hand, the melting temperature of this material is very low (180 °C) compared to conventional metals, rendering it problematic a stable thermal cutting operation. While the laser is an appealing solution for scaling up the cutting process of lithium metal, the ideal laser type to be used for this operation still requires further attention. Accordingly, this work investigates impact of continuous wave and ns-pulsed laser sources on the cut quality and productivity of 50 µm-thick pure Li sheets. Processing conditions are discussed to address the environmental control issues for reactivity along with the different processing regimes observed.

This study highlights a groundbreaking advancement in Direct Laser Interference Patterning (DLIP) by integrating a high-power multimode fiber laser, traditionally used for macro fabrication, into precision microfabrication processes. By employing an innovative beam-shaping system, the challenges associated with the low coherence and beam quality of multimode lasers are effectively addressed, enabling the generation of well-defined periodic structures on large surface areas. This novel approach demonstrates the feasibility of utilizing multimode fiber lasers for high-resolution microstructuring, thus marking a significant shift in their application scope. The findings open new opportunities for integrating these versatile and high-power lasers into industrial-scale microfabrication, offering efficiency, scalability, and precision.

Laser cutting of electrode foils is a critical step in Li-ion battery manufacturing, with high single-pass speeds along with excellent quality being required. While demands have previously been met by infrared fiber laser technology, producers are increasingly turning to high-power ultrashort pulse (USP) lasers as quality requirements continue to increase. In this work, we present results for laser cutting graphite-based anode and NMC cathode battery materials. The foils are ~100 µm thick and double-side coated with the respective active material. Using 200 watts of IR femtosecond laser power, single-pulse cutting processes were developed and optimized, followed by a burst-optimization scheme using the laser’s flexible pulse-tailoring capability. When bursts were optimally applied, cutting speeds improved by up to ~45%. Analysis includes optical and scanning electron microscopy, with particular attention given to the cut edge quality and the amount of excess active coating material removal.