As the production of light aircraft surged, reaching an annual output of more than 5,000 aircraft and the influx of funds for electric vertical takeoff and landing aircraft (eVTOL) of more than 10 billion US dollars, it indicated that the aviation industry was entering a revolutionary era. Battery pack is the core of this transformation, and its safety, weight and reliability will directly determine the feasibility of the next generation of aircraft. Traditional spot welding is widely used, but it can’t meet the strict requirements of the current advanced aviation industry. But transistor welding technology redefines this field.
Aircraft-grade battery packs have extremely high welding requirements for quality. Six-series aluminum (used to reduce weight), nickel-plated steel (used to improve corrosion resistance) and copper-aluminum composite materials are dominant. However, the traditional spot welding equipment can not meet the requirements of the above materials. Uneven welding power distribution is easy to cause splash cracks. After welding, X-ray inspection results show that up to 30% of welds are unqualified. Its heat affected zone (HAZ) exceeds the strict limit of 0.2 mm, which will damage the chemical composition of the battery and accelerate the battery decay. What’s worse, the traditional spot welding equipment lacks real-time traceability of welding pressure parameters, which makes the process monitoring and welding data lack. And the transistor welding equipment completely solves this pain point by monitoring and recording the pressure data of each solder joint in real time.
Styler Electronic’ transistor welding machine solves these pain points through microsecond control and precision welding innovation. Its 20k Hz–200kHz high frequency inverter can realize programmable current waveform (DC, pulse or ramp), thus achieving welding accuracy of 0.05mm. Which can increase the accuracy of the battery pack, which is very important for aviation safety.
Transistor welding power supply adopts IGBT and other high-speed switching transistors, which can output highly stable direct current, and rely on high-frequency inverter technology (such as 20kHz) to realize accurate programming control of current waveform. Its core lies in the systematic suppression of welding defects through the complete process sequence of “gradual ascending slope-smooth welding-gradual descending slope”. At the same time, the microprocessor built in the power supply monitors the current and voltage in real time at microsecond frequency, and the welding current is firmly “locked” at the set value by dynamically adjusting the IGBT switch state. It can effectively resist the disturbance caused by the dynamic change of resistance in the welding process, fundamentally avoid the overheating splash caused by the sudden change of current, and ensure the extreme stability of heat input.
The case study highlights its advantages. 0.3mm-thick Al-Ni steel joint reaches 85% of the strength of base metal under ASTM E8 standard, and can withstand extreme vibration. Its energy efficiency is as high as 92%. Compared with traditional welding machines, the energy consumption is reduced by 40%, and each medium-sized production line can save 12,000 dollars every year. The pre-installed DO-160G compliance can improve the certification speed by 30% and is supported by EASA technical certification.
For aircraft original equipment manufacturers, battery pack manufacturers and R&D laboratories, Styler’s transistor welding machine goes beyond the scope of welding tools. Like a shield of compliance, it turns regulatory obstacles into competitive advantages. Each welding becomes a traceable and readily available data point, which conforms to ISO3834 and RTCA DO-160 standards.
Precision welding is no longer an option, but a foundation with the transition of electric vertical takeoff and landing aircraft (eVTOL) from prototype to passenger fleet. Styler invites manufacturers to experience millimeter precision through live demonstration. Find out how our battery welding technology turns risk into reliability. Contact us for more details and redefine your aviation welding standards, so that every welding is born for flying in the blue sky.
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(Credit: pixabay lmages)
Post time: Nov-13-2025
