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ANCA Sheet Metal Solutions Appoints Nicholas Doyle As General Manager

ANCA Sheet Metal Solutions Appoints Nicholas Doyle As General Manager

Nicholas Doyle replaces Frank Holzer as the General Manager of ANCA Sheet Metal Solutions (ASM) at a time of significant growth for the company. Nicholas brings over 25 years’ experience in leadership, engineering, manufacturing, systems and quality to help strengthen the business.

“It is an exciting time to join ASM as we continue to welcome new customers and take on exciting projects. Moving to the new facility in 2019 brought a new era of professionalism in our 20-year history. As well as a new name and brand, the changes that Frank led in 2019 set up ASM with the capabilities to grow our manufacturing capacity and offer our customers even greater quality solutions,” said Nicholas Doyle, ANCA Sheet Metal Solutions General Manager.

ASM are an Australian owned business and offer a comprehensive set of services integrating cutting-edge sheet metal fabrication equipment with a workforce of qualified manufacturing engineers, technicians and welders. The skilled team, based in Thailand, are practiced in transforming a concept into a well-priced, high quality product.

“We offer a premium service with capabilities in engineering; laser cutting; waterjet cutting; folding and forming equipment; welding and painting; assembly and testing and take a lean manufacturing approach. It is a pivotal time to join ASM, as we build on our foundations to produce high quality metal fabrication products – growing our product ranges and manufacturing team,” Nicholas concluded.

Nicholas, a qualified Engineer, worked as a Mechanical Engineer at Bredo Mators in Melbourne, Australia before joining the ANCA Group as a CAD CAM Engineer. After four years working for ANCA Australia he moved to ANCA CNC Machines Thailand to manage the factory transition into a larger facility and subsequently became the Manufacturing Manager for that new Thailand facility.

Bringing over 25 years’ experience in CNC machining and automation, Nicholas will focus on cost reduction and process improvements and aims to develop a strong ASM team focused on customer satisfaction.


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Laser Applications In The Production Of Li-Ion Battery Cells And Packs

Laser Applications in the Production of Li-Ion Battery Cells and Packs

The laser is at the center of many solutions when it comes to the global e-mobility trend. Here are a few examples of laser cutting applications in battery cell manufacturing and assembly. Article by Trumpf.

The worldwide mobility transition is in full swing. The demand for components for electric cars and alternative drives is rising continually. In particular, high-performance components directly involved in the production of batteries, electric motors and power electronics for electromobility are at the center. More and more companies, predominately automotive suppliers, are also demanding new manufacturing solutions and technologies for alternative drive concepts, including the fuel cell.

The laser is at the center of many solutions. It connects battery cells into modules or packs. It ensures tightness and crash safety when joining battery packs and trays. It scores highly thanks to its green wavelength when copper welding contact parts without spatter. And it provides high-tensile connections in e-drives, which withstand the highly dynamic requirements.

Manufacturing Battery Cells

Battery cell manufacturing is subdivided into electrode manufacturing and cell assembly. Electrode manufacturing requires a high variety of different process steps: mixing of the slurry, coating, drying, calendaring as well as shaping, folding and stacking of the coated electrode foil. Some of them required laser technology:

  • Micro structuring of the electrode surface with ultra-short pulse lasers, for example, reduces subsequently the charging time of battery cells.
  • Drying of electrodes with VCSEL laser technology to complement conventional drying ovens by reducing the footprint and increase efficiency.
  • Cutting and shaping of coated electrode foils with ns lasers into the required format, increasing quality and productivity. Common foil materials are aluminium (cathode) with a 5-14 µm thickness as well as copper (anode) with a thickness of 9-13 µm. Very often, these foils are coated. Cutting these foils with TruFiber laser sources enables burrs of less than 5 µm and HAZ of less than 40µm. 

In the cell assembly, the steps are contacting, packaging, formation, and aging. Laser technology is used here mainly in welding applications for the internal contacting of battery cell components and the closing of prismatic cell formats:

  • Green laser wavelength for the very defined and repeatable welding of copper materials.
  • High power IR lasers combined with Trumpf’s BrightLineWeld technology for spatter free welding of aluminium or copper materials.

Both laser applications enable the highest mechanical strength and lowest electrical resistance in welding of ≤100 foils together to a stack.

On the cell level, besides these different welding applications, there are also some upcoming laser applications for surface processing like cleaning, de-coating or micro structuring with short or ultra-short pulse lasers.

Process stability is a key factor in the battery cell production. Therefore, all these laser technologies have a direct impact on the efficiency and performance of the battery.

Battery Module Assembly

After the battery cell manufacturing process, the single cells will be assembled to a battery module. The electronics and battery pack assembly have an enormous variance of different module designs. But all are based on prismatic, pouch or cylindrical cell formats.

Laser technology is used in welding of busbars, meaning the electrical contacting of single cells to a battery module, or other current carrying components. Due to the enormous number of different designs, material combinations and thicknesses, the full TRUMPF laser portfolio in terms of power, wavelength, beam quality is applied.

  • Especially for thicker aluminium busbars with welding depths mostly >2 mm and welding speeds of minimum 100 mm per second, the TruDisk laser series with patented beam shaping technology BrightLineWeld is the best choice since every single weld must be exactly the same and spatter projections must be avoided.
  • For the welding of dissimilar material combination like Al/Cu or Al/steal, we mostly recommend single mode IR lasers with a very high beam quality e.g. you can use the TruFiber Series for such applications. These lasers create a very small intermetallic phase in the welding seam, which is important for a strong joint of materials with quite different melting temperatures. By using different welding patterns, you can join Al with Cu or even the other way around. Typically, by oscillating the laser beam with a scanner optic to increase the cross-section area. For the contacting of cylindrical cells, the sheet thicknesses are usually in the range 0.2 – 0.5mm, and many times dissimilar material combinations or with coatings.

For most of the installations in battery and module manufacturing, TRUMPF lasers, optics and sensors are integrated in automated high-volume production lines, while its TruLaser Station and TruLaser Cell series are suitable in small- and medium-production volumes.


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LVD Launches New Large-Format Laser Cutting Machine

LVD Launches New Large-Format Laser Cutting Machine

LVD launches Taurus FL, a new large-format gantry-style fiber laser cutting machine engineered for extra-large sheet metal cutting capacity. A unique modular design, the machine size begins at a 12-meter bed length and can be expanded in increments of 2 meters to a maximum bed length of 40 meters to suit user needs. The large format allows a diverse range of parts to be cut and efficiently nested, increasing productivity and optimising material usage.


Taurus FL delivers the flexibility to process extra-large sheets or multiple sheets, cut a range ensure high machine dynamics of jobs in varying batch sizes, shapes and material types accommodating workpieces up to 3.3 meters wide and up to 30 mm thick.

Large parts can be processed without repositioning while multiple smaller workpieces can be positioned on the cutting table and processed in continuous fashion, without interruption. Parts can be cut on one section of the table, while loaded/offloaded on another, keeping downtime to an absolute minimum.

Taurus FL is designed for easy access. Only the gantry features an enclosure, not the complete machine. The mechanical design and drive system ensure high machine dynamics in large-format cutting.

The operator has use of two touch panels for convenient access to the control at all times.

A handheld control unit enables the operator to safely move all axes in manual mode for machine setup or to load the nozzle changer. A camera located inside the cutting zone and a monitor on the operator console allow continuous monitoring of the cutting process. The cutting zone has a detachable front panel, providing access for maintenance.

No special foundation is required for the machine.


Taurus FL also provides the option of beveling cutting or 2.5D cutting up to 45°. The fiber laser is an ideal tool for reliably producing high-quality bevel cuts in a large-format cutting platform. The bevel cutting option offers a fast and cost-effective way to prepare material for subsequent welding operations or to create geometrical shapes.

The Taurus FL bevel head uses two direct-drive motors. The direct-drive principle uses no transmission components resulting in the highest possible accuracy and a fast responding system. As a result, consistently precise bevel cutting is assured.

The bevel head is able to cut on a horizontal surface as well as cut shapes in pre-formed parts or cut under angle within the limits of the Z-axis and +/- 45 deg.

An optional automatic nozzle changer increases machine uptime and throughput. The unit has storage for 30 nozzles in a turret-style holder positioned close to the cutting head. The nozzle changer features an integrated camera that checks nozzle alignment, size and condition. It offers automatic calibration of the capacitive height sensing and nozzle cleaning after a preset number of piercings.

Optional CADMAN-L software includes automated functions to simplify programming and offers advanced nesting, collision avoidance, On-the-Fly Piercing and Cutting, and process parameter tables to realise the full potential of Taurus FL. For bevel cutting, an optional plug-in is available for SolidWorks, Solid Edge and Inventor.

Taurus FL is offered with a 6-, 8- or 10-kW fiber laser source, which boasts an industry-leading wall-plug efficiency of more than 40 percent.

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