Integrated Joining Technologies for High-Performance Functional Components—the Modular Joining Platform

The demands placed on modern products are constantly increasing. Electrification, miniaturization, new material combinations, and higher demands on reliability and service life mean that traditional joining solutions are increasingly reaching their limits. KERN LIEBERS therefore develops joining technologies not in isolation as a manufacturing process, but as an integral part of the entire product system.

At the heart of this approach is a systemic development strategy that considers materials, component design, process control, tooling technology, and industrialization as a unified whole. This results in joints that not only permanently join components but also specifically support and ensure electrical, thermal, and mechanical functions.

The result is robust, scalable, and cost-effective manufacturing solutions with high process reliability and reproducible product properties.

From the Weld to the Functional Joint

While traditional welding technology often focuses on strength and process parameters, we view the joint as a functional system element. Aspects such as electrical conductivity, thermal behavior, long-term stability, service life, and robustness under real operating conditions are taken into account as early as the development phase.

This lays the foundation for innovative applications in areas such as:

• Battery technology and energy storage
• Power electronics
• Contact and connection technology
• Sensors and actuators
• Electric mobility
• Industrial Energy Systems

Example: A New Approach to Friction Stir Welding

A key focus of our research activities is the further development of friction stir welding for high-power electrical applications. Through new tool concepts, innovative process strategies, and the targeted design of the joint zones, we can create copper, aluminum, and mixed-material joints with high electrical performance and mechanical strength.

In addition, we are developing new solutions for lamellar systems, contact technologies, battery connections, and hybrid material systems, thereby opening up new fields of application for functionally optimized joining technologies.

Our Mission

We view joining technology not as a single manufacturing step, but as an enabler of modern products. Our goal is to enable functions, simplify components, and sustainably increase the performance of technical systems. In this way, a joint becomes a decisive contribution to product functionality.