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The FSW-BL3020 is engineered for manufacturers producing large-format EV battery trays, battery enclosures, and structural battery housings.
As battery systems continue to increase in size and complexity, manufacturers require welding equipment capable of maintaining dimensional accuracy, leak-proof performance, and production consistency across large aluminum assemblies.
Traditional fusion welding methods often introduce excessive heat, resulting in distortion, porosity, weld defects, and costly post-processing operations. Friction stir welding eliminates these challenges through a solid-state joining process that produces stronger, cleaner, and more reliable welds.
With its large-format gantry structure and intelligent CNC control system, the BL3020 provides a stable and efficient manufacturing solution for modern EV battery tray production.
Manufacturers looking for larger production capacity or multi-station battery pack welding systems can also explore our large gantry friction stir welding machine solutions for EV battery manufacturing.
Manufacturers of EV battery trays and battery enclosures often face several production challenges:
Distortion of large aluminum trays caused by excessive welding heat
Leakage risks within liquid-cooled battery systems
High scrap rates resulting from porosity and weld defects
Dimensional inconsistency across oversized battery structures
Costly rework and post-machining requirements
Difficulty maintaining stable quality in mass production environments
The BL3020 addresses these challenges through precise process control, stable welding force, and repeatable weld quality.
EV Battery Trays
High-strength welding for electric vehicle battery tray assemblies.
Aluminum Battery Enclosures
Reliable joining of large aluminum battery housing structures.
Structural Battery Platforms
Suitable for next-generation structural battery pack designs.
Battery Cooling Structures
Leak-proof welding for integrated cooling channels and thermal management systems.
Energy Storage Battery Housings
Stable welding for industrial and stationary energy storage systems.
Large Aluminum Battery Components
Applicable to customized battery structures and lightweight energy systems.
Battery trays serve as the foundation of modern electric vehicle battery systems. These structures must provide mechanical strength, dimensional stability, impact resistance, and long-term sealing performance.
Traditional welding methods such as MIG and TIG welding generate significant heat input, which can lead to distortion, porosity, cracking, and inconsistent weld quality. These challenges become more critical as battery trays increase in size and complexity.
Friction stir welding offers a superior solution by joining aluminum materials in a solid-state condition without melting the base material.
Compared with conventional welding methods, friction stir welding provides:
Significantly lower thermal distortion
Improved dimensional stability
Reduced porosity and weld defects
Superior leak-proof performance
Higher mechanical strength
Consistent weld quality across production batches
Reduced post-processing requirements
For EV battery tray manufacturers, friction stir welding improves both product quality and production efficiency.
Designed for Large Battery Tray Production
Large-format working area supports oversized EV battery structures.
Leak-Proof Welding Performance
Ideal for battery trays containing cooling channels and liquid cooling systems.
High Structural Integrity
Produces strong weld joints with excellent mechanical properties.
Low Distortion Welding Process
Minimizes thermal deformation on large aluminum assemblies.
Intelligent CNC Control
Provides stable process control and consistent weld quality.
Automation Ready
Supports integration with automated production systems and robotic handling solutions.
Machine Model: FSW-BL3020
Machine Structure: Gantry Type
Workbench Size: 3000 × 2000 mm
XYZ Travel: 3000 × 2000 × 500 mm
Gantry Width: 2400 mm
Welding Head: 3T Standard / 6T Optional
Welding Depth: ≤10 mm (3T) / ≤20 mm (6T)
Welding Force: 30 kN / 60 kN
Spindle Speed: Up to 4000 rpm
Positioning Accuracy: 0.05 mm/m
Power: 25 kW / 30 kW
Control System: CNC Intelligent Control
Automation Compatibility: Yes
Applicable Materials: Aluminum Alloys, Magnesium Alloys, Copper Alloys
Name FSW-BL3020 | Technical Index |
Workbenches | T-shaped groove/M16 matrix threaded hole |
Equipment footprint | About 7500x3460x3200mm |
Z-direction space (From the lower end face of the spindle to the upper surface of the worktable) | 870mm/840mm* |
Longmen Pass Width | 2400mm |
Workbench size | 3000mm(X)×2000mm(Y) |
XYZ axis travel | 3000x2000x500mm |
B-axis travel | 0°~+5° (Manually adjustable) |
C-axis travel | ±360° |
X-axis movement speed | 0- 10000/6000*mm/min |
Y-axis movement speed | 0- 10000/6000*mm/min |
Z-axis movement speed | 0-5000/3000*mm/min |
C-axis speed | 20rpm |
Spindle speed | ≤4000rpm/3000rpm* |
X-axis positioning accuracy | 0.05mm/m |
X-axis repeat positioning accuracy | 0.03mm/m |
Y-axis positioning accuracy | 0.05mm/m |
Y-axis repeat positioning accuracy | 0.03mm/m |
Z-axis positioning accuracy | 0.03mm/m |
Z-axis repeat positioning accuracy | 0.03mm/m |
Total weight of equipment | About 15t |
Total power of equipment | About 25kW/30kW* |
Battery tray production requires more than welding capability alone. Manufacturers must also control scrap rates, production efficiency, dimensional accuracy, and overall manufacturing costs.
The BL3020 helps improve manufacturing efficiency by reducing common welding defects such as porosity, cracking, excessive deformation, and leakage issues.
Its large-format design allows manufacturers to process larger battery tray assemblies while maintaining stable welding quality throughout the entire structure.
Benefits include:
Reduced scrap and rework rates
Improved dimensional consistency
Better leak-proof performance
Lower post-processing requirements
Increased production stability
Higher manufacturing efficiency
Reduced overall production costs
The FSW-BL3020 is specifically engineered for manufacturers producing large EV battery trays, battery enclosures, and structural battery systems.
Positioned between medium-size fabrication equipment and high-volume production platforms, the BL3020 offers an ideal balance of welding capability, production flexibility, and equipment investment.
Optimized for EV battery tray manufacturing applications
Large-format working area for oversized battery structures
Stable welding quality across long weld paths
Excellent repeatability for both prototype and production projects
Intelligent CNC control for process consistency
Automation-ready design for future production upgrades
Suitable for battery trays, battery enclosures, and structural battery platforms
As battery systems continue to evolve toward larger and more integrated designs, the BL3020 provides manufacturers with the flexibility and reliability required for long-term production growth.
For complete large-format battery tray welding solutions:
Large Gantry Friction Stir Welding Machines
For medium-size aluminum structural assemblies:
FSW-BL2520 Precision Friction Stir Welding Machine
For high-volume battery pack production:
FSW-DM5020 Multi-Station Friction Stir Welding Machine
For EV battery tray welding services and prototype validation:
For friction stir welding tools and consumables:
The BL3020 is suitable for EV battery trays, battery enclosures, structural battery platforms, battery cooling structures, and customized aluminum battery housings.
Yes. Friction stir welding produces dense weld structures with excellent sealing performance, making it highly suitable for battery trays containing cooling channels and liquid cooling systems.
The solid-state welding process minimizes distortion, reduces porosity, improves sealing performance, and produces stronger weld joints for battery systems.
The BL3020 supports aluminum alloys, magnesium alloys, copper alloys, and selected dissimilar metal applications depending on project requirements.
Yes. The machine supports robotic handling systems, automated fixtures, intelligent monitoring systems, and customized automation solutions for large-scale EV battery manufacturing.
By reducing weld defects, minimizing tray deformation, lowering rework rates, and improving production consistency, the BL3020 helps manufacturers reduce overall manufacturing costs while improving throughput.
Planning a New EV Battery Tray Project?
Whether you are developing aluminum battery trays, battery enclosures, structural battery platforms, or liquid-cooled battery systems, our engineering team can help evaluate your application and recommend the most suitable friction stir welding solution.
Send us your drawings, material specifications, production volume, and welding requirements today.
We will provide:
Project feasibility evaluation
Recommended machine configuration
Welding process suggestions
Automation integration options
Production efficiency recommendations
Start your EV battery tray manufacturing project with a friction stir welding solution designed for leak-proof performance, dimensional stability, and long-term production efficiency.
