Laser applications in power electronics
Power electronics are found in nearly all modern applications — from electric vehicles and power converters to industrial drives. They control, convert, and distribute electrical energy efficiently and reliably. With ongoing miniaturization and increasing demands for precision and efficiency, laser technologies are becoming increasingly important in the development and manufacturing of power electronic systems.
Laser technology: the backbone of modern power electronics
The precise manufacturing of power electronic components requires the highest accuracy and consistent, reproducible quality. Laser-based production processes enable interventions on the micro- and sub-micrometer scale without mechanically stressing the component.
What is meant by power electronics?
Power electronics is a central field of electrical engineering that deals with the conversion, control, and regulation of electrical energy. It examines how electrical power flows can be guided efficiently and focuses on the behavior and driving of components such as transistors, diodes, or thyristors. At the same time, it analyzes how these systems interact with the grid and other electrical components.
Fundamentals of electrical power
Electrical power is described by the following formula:
- P stands for power in watts (W)
- U stands for voltage in volts (V)
- I stands for current in amperes (A)
This simple formula illustrates a key principle: the higher the voltage or current, the greater the amount of power being transferred — and the more important precisely controlled electronic components become.
Structure of power electronics
At the core of power electronics are semiconductor switching devices. They control the flow of electrical energy, switch high currents and voltages, and form the foundation of nearly all modern applications. The most common semiconductor switching devices are transistors, diodes, and thyristors:
Transistors
Transistors are controllable electronic components used in many types of circuits. As active switches, they allow current to be directed through a circuit or interrupted, making them indispensable for the precise control of electrical energy.
Diodes
Diodes are electronic components that allow current to flow primarily in one direction. They have an anode and a cathode and can also be used as switches. Compared with transistors, they are simpler to use and particularly robust.
Thyristors
Thyristors can handle high voltages and currents. They make it possible to control the energy flowing through them with precision and are mainly used in high-power systems.
Power electronics in everyday life
Power electronics accompany us in everyday life, often without us noticing. Whether in household appliances, computers, chargers, or electric drives—power electronic systems ensure that electrical energy is controlled and used efficiently everywhere.
Practical example: photovoltaic systems
Power electronics also play a key role in photovoltaic systems. Solar cells first generate direct current, which is converted into grid-compatible alternating current by an inverter. At the same time, power electronic systems regulate the optimal operating point of the system to extract as much energy as possible from the available sunlight.
Laser-based manufacturing steps in power electronics
With continuous advancements in power electronics, the demands placed on manufacturing technologies are steadily increasing. Components such as transistors, diodes, and thyristors are becoming more compact and more powerful while also needing to operate with extremely high reliability. To achieve this level of precision, laser technologies are being used more and more in production.
Importance of laser applications in power electronics
Conventional manufacturing methods quickly reach their limits when it comes to reliability, precision, and efficiency. Even minor inaccuracies can lead to performance losses or damage, which is why laser applications offer decisive advantages:
- High precision: Lasers can process structures in the micrometer range. This is particularly important for accurately shaping thin conductor paths, fine contacts, or delicate semiconductor wafers.
- Contact-free operation: Unlike mechanical processes, the laser does not physically touch the material. This minimizes the risk of damage or wear.
- Minimal heat input: Because energy is applied in a highly targeted manner, the surrounding material heats up only minimally. This prevents warping, stress, or material damage and ensures durable, reliable components.
- Versatility in manufacturing: Lasers can be used for a wide range of tasks—from welding and cutting to structuring, dicing, or even repairing minor defects.
- Efficiency and automation: Laser processes can be precisely controlled, easily repeated, and integrated into automated production lines, increasing both production speed and quality.
What are laser applications used for in power electronics?
Lasers play a central role in the manufacturing of power electronic components, enabled by laser systems. Their areas of application can be broadly divided into the following categories:
Laser welding
- Joining metallic contacts, conductor paths, or busbars
- Especially important for small, delicate components
- Creates stable, long-lasting electrical connections
- Precisely forming or separating fine conductor paths on circuit boards or semiconductor wafers
- Enables miniaturization and high component density
Laser dicing/wafer separation:
- Accurate singulation of semiconductor wafers (e.g., Si, SiC, GaN) into individual chips, as performed with systems such as the WT35X0
- Minimizes microcracks, particle contamination, and mechanical stress
- Selective removal or contouring of wafer edges, removal of defective edge zones, or adjustment of wafer diameter
- Often used as a preparatory step before dicing or packaging
Laser drilling and micromachining:
- Creating microholes, channels, or cooling structures in components
- Enables innovative designs and improved performance
Repair and quality control:
- Correction of minor defects or microstructures
- Analysis and optimization of component quality without causing damage
Process optimization and automation:
- Repeatable, highly precise manufacturing processes
- Easy integration into automated production lines
- Increases efficiency and yield
Future trends in laser manufacturing for power electronics
The manufacturing of power electronic components is becoming increasingly demanding. Ultrashort laser pulses enable highly precise processing of sensitive materials. Artificial intelligence supports production by monitoring processes in real time, detecting deviations, and automatically optimizing parameters—improving both quality and efficiency. At the same time, these technologies help conserve materials and make manufacturing more sustainable.