Application of Laser Welding for Terminal Connections in AI Servers

With the rapid growth of artificial intelligence computing and large-scale data centers, AI server architectures are evolving toward higher power density, greater integration, and stricter reliability requirements. In this context, electrical interconnection quality has become a critical factor affecting overall system performance and stability.

Traditional terminal connection methods, such as mechanical crimping and soldering, are increasingly challenged by high-current operation, thermal cycling, and long-term reliability demands. As a result, laser welding for terminal connections has emerged as a promising advanced manufacturing process for next-generation AI server production.

This technology uses a high-energy-density laser beam to achieve precise localized melting between electrical terminals and conductive materials, forming a stable metallurgical bond. Compared with conventional processes, laser welding offers significantly lower contact resistance, improved mechanical strength, and superior consistency in mass production. These advantages make it particularly suitable for high-performance computing systems, including AI server power modules and high-speed electrical interconnects.

Within AI server systems, terminal connections perform critical functions such as power delivery, signal transmission, and high-speed interconnects, and their quality directly affects energy efficiency, thermal stability, and overall system reliability, making terminal joining a key process in advanced server manufacturing. Laser welding for terminal connections enables precise energy control and localized metal fusion at the microstructural level, forming stable metallurgical bonds with minimal defects, and effectively eliminating issues such as cold joints, voids, and inconsistent contact quality compared with traditional soldering. In high-load AI server operation, elevated current density can cause localized heating and energy loss due to contact resistance, while laser-welded connections significantly reduce electrical resistance and improve power efficiency and thermal management performance. The process is highly compatible with automated production lines, supporting high-speed, high-precision, and highly consistent manufacturing required for rapid iteration and large-scale deployment of AI servers. As system architectures evolve toward modular and ultra-high-density designs, laser welding provides micron-level precision for compact structures such as GPU power modules, power distribution assemblies, and high-density PCB interconnects. It is compatible with copper, aluminum, and composite conductive materials, enabling flexible design optimization for performance and cost, and has been widely applied in server power modules, backplane interconnects, GPU power systems, and Power Distribution Units (PDUs). From a smart manufacturing perspective, laser welding supports digital production through machine vision inspection, process monitoring, and real-time feedback control, ensuring full traceability and stable weld quality in high-reliability AI server manufacturing.

HGTECH QCW laser welding intelligent equipment is designed for precision applications such as AI server terminals and high-speed connectors. It features quasi-continuous wave (QCW) control and a high beam quality laser source, enabling energy modulation for low spatter and micron-level welding accuracy. The heat-affected zone is reduced by 50% compared with conventional processes, minimizing thermal damage and ensuring stable welding of reflective materials like copper and aluminum.

The system delivers 3–5 times higher efficiency than traditional methods, is consumable-free, and reduces maintenance costs by around 60%. It can be integrated into smart manufacturing lines for high-consistency mass production and is already widely used by leading AI server manufacturers as a key solution for advanced terminal connection processes.

For server manufacturers, adopting laser welding for terminal connections is not only a process improvement but also a strategic step toward higher product competitiveness and manufacturing capability. With further integration of intelligent control systems, advanced laser sources, and digital manufacturing platforms, this technology is expected to play an increasingly important role in the evolution of high-end AI server production and next-generation electronic assembly processes.

About HGTECH

HGTECH is the pioneer and leader of laser industrial application in China, and the authoritative provider of global laser processing solutions. We comprehensively layout the construction of laser intelligent equipment, measurement and automation production lines, and smart factories to provide an overall solution for intelligent manufacturing.

We deeply grasp the development trend of manufacturing industry, constantly enrich products and solutions, adhere to exploring the integration of automation, informatization, intelligence and manufacturing industry, and provide various industries with laser cutting systems, laser welding systems, laser marking series, laser texturing complete equipment, laser heat treatment systems, laser drilling machines, lasers and various supporting devices The overall plan for the construction of special laser processing equipment and plasma cutting equipment, as well as automatic production lines and smart factories.