Power electronic components require both efficient assembly and safe, reproducible testing. Based on our experience in testing complex systems, we develop customized solutions for reliable quality assurance throughout the entire production process.

Our test systems cover a wide range of applications, including EOL testing, functional testing, leak testing, flashing, communication testing, run-in & burn-in testing, as well as various simulations, including active-load simulations. Using our in-house equipment, including the equipment available in our electronics laboratory, we can develop the test bench software as early as the assembly phase of the stations. The equipment is designed to be flexible enough to perform the required tests as well. This helps to shorten project lead times.

In close cooperation with our customers, we identify potential for optimization at an early stage. Failure analyses, process adjustments, and validation activities can also be carried out in our electronics laboratory without affecting ongoing production.

Another important aspect is the in-house development of electrical contacting solutions for our test systems. Depending on customer requirements, these are developed by our engineering team and manufactured at Sonplas. This provides additional flexibility for individual projects.

We develop customized solutions for battery production across the entire value chain. For laser processing of cathode and anode materials, our systems enable precise notching, slitting, and singulation with clean, burr-free cutting edges. They can be integrated flexibly and reliably into existing production lines.

We design scalable systems for the precise assembly of battery modules and packs, tailored to individual production requirements and capacity needs.

Our test systems ensure the quality and performance of cells, modules, and packs throughout the production process. The portfolio ranges from production-integrated end-of-line testing to performance, safety, and endurance testing under defined conditions.

By combining precise manufacturing, scalable assembly, and reliable testing, we support the development and production of high-performance, safe, and economically viable battery systems.

Laser cutting in the converting industry enables the highly precise and cost-effective processing of sheet-like materials such as films, metals, plastics, and textiles. Sonplas’ innovative laser cutting systems produce precise, burr-free cut edges – contact-free, without tool wear or material deformation. The technology is used in applications such as fuel cells and printed electronics as well as metalworking, the plastics and textile industries, the paper and solar sectors. Our laser systems enable customized notching, slitting, and separation processes – automated, efficient, and at the highest quality level.

We develop customer-specific assembly systems for power electronics – from prototype production to fully automated, high-volume series production. From the beginning, we consider all relevant requirements, including product design, production volumes, and the desired level of automation.

This includes various assembly processes such as screwing, dispensing, press-fit, and laser welding of busbars, as well as packaging processes including labeling and laser applications. Depending on the customer’s requirements, these processes are integrated into the respective systems.

Depending on the required production volume, our systems typically achieve cycle times between 20 and 300 seconds. Other cycle times can also be implemented to meet individual production requirements.

We take responsibility for the entire project – from initial planning and system development through implementation and production launch. With our experience in power electronics, we support our customers throughout the entire process – from the first concept to stable series production.