There are many materials joining requirements in battery manufacture. Depending on the size, type, and capacity, these include both internal and tab-to-terminal connections, can and fill plug sealing, and external connections. Several joining options can be considered including ultrasonic , resistance (spot), and laser welding. Ultrasonic welding is most often used to join the internal electrode battery materials which are typically constructed of thin foils of copper and aluminum. The remaining joins - including connections inside the can, and external terminal tab connections - are suited to both spot and laser welding The decision to use one technology or the other is determined both by the type of weld required and production requirements.

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