HEAT: Heat is critical to achieving the correct temperature for diffusion bonding, which must remain below the melting point but high enough to activate solid-state welding. Accurately controlling this temperature is essential because deviations can either fail to activate the diffusion process or cause material deformation.

FORCE: Force is also an important parameter to a controlled diffusion welding process, and a vital one for a faster process, or for a process over a large welding area. Diffusion Welding will happen uniformly and repeatably only if the force is CONSTANT over ALL the surface, to allow the current to heat the parts homogeneously.

TIME: Provided both temperature and force are stable, and the target temperature is achieved, a timer will govern the welding cycle according to the predefined recipe. Excessive time can lead to material degradation, while insufficient time can produce weak bonds.

PLANARITY AND LARGE AREA DIFFUSION WELDING: Achieving perfect planarity across the welding surface ensures uniform heat and force distribution. This becomes increasingly difficult as the size of the part and the welding area increases. Factors such as material irregularities and thermal expansion can introduce distortions that affect the quality of the weld.
TECNA’s patented perfect planarity improves the handling of large area multi point projection welding.

The primary differentiator lies in how these parameters are controlled and combined to produce consistent, high-quality results, especially as the welding area increases in size.

EV Battery Packs and Busbars

Diffusion welding is ideal for joining copper flexible busbars, laminated copper foil connectors, braided connectors, and battery current-carrying components. By forming high-integrity solid-state bonds without melting the base materials, it improves joint strength, electrical conductivity, thermal performance, and process repeatability for high-current EV battery applications.

Energy Storage Systems

Suitable for energy storage copper busbars, aluminum conductors, flexible connectors, laminated busbars, and composite conductive parts. Diffusion welding creates strong, metallurgical bonds with minimal electrical resistance, helping reduce contact resistance variation, minimize localized overheating, and improve long-term reliability in high-current energy storage applications.

Power Distribution Equipment

Designed for copper busbars, flexible braided connectors, switchgear conductive parts, and power connection assemblies. Diffusion welding enables large-area conductive joining with precise pressure and temperature control, helping improve joint strength, electrical conductivity, and long-term reliability for demanding power distribution applications.

Automotive Electrical Components

Designed for conductive connectors, power modules, EV electrical components, battery terminals, and high-current connection assemblies. The controlled diffusion welding process delivers consistent bond quality, excellent electrical conductivity, and repeatable weld performance while supporting process traceability and quality assurance for high-volume automotive manufacturing.

Flexible Busbar Manufacturing

Suitable for manufacturing flexible copper busbars, laminated foil busbars, and braided conductive connectors where bond integrity, electrical conductivity, and surface quality are critical to overall performance. Controlled heat and pressure deliver consistent welds that help minimize contact resistance while improving joint strength, dimensional stability, and production repeatability.