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Battery Copper Tabs

Battery Copper Tabs

Weld Copper Battery Tabs

Weld copper battery tabs for EV, PHEV, and Hybrid Packs, Buss Bars, and Terminal Termination.  Also weld Aluminum to Aluminum, Copper to Copper, or Aluminum to Copper.

Copper is a notoriously difficult metal to weld.  It has a high thermal conductivity and electrical conductivity.  This means that a resistance welding process generally has difficulty producing enough heat at the copper-weld interface to produce a weld.  What little heat that is produced is quickly wicked away by the surrounding metal.    Copper is also difficult for most laser welders.  The typical YAG laser wavelength is at around 1064 nm.  At this wavelength over 90% of the light energy is reflected away from the surface of the copper.  Green wavelength lasers have been developed to help overcome this problem but their cost is highly prohibitive for most businesses.

Sunstone Engineering has developed a welding technology that overcomes the limitations of both resistance and laser welding. Sunstone’s Omega PA250i welding system uses pulse arc technology to melt the copper sheet in a spot and gently lay that molten material down on a battery can surface.  As with other pulse arc welds, the weld happens quickly and the energy added in the form of heat to the battery is very low.  The end results is a high conductivity copper sheet can be welded easily to a steel or nickel battery can surface in thicknesses that are much larger than traditional resistance welding of nickel tabs.  This thicker, highly conductive copper can reduce the power drop in the battery pack significantly – especially for high current batteries packs.  This means cooler batteries, longer battery life, more voltage, current, and power from your packs!

What are you welding today? Call or text us at +1-801-658-0015.

Omega PA250i Copper Tab Battery Welding

Overview and Applicationssunstone-pa250i-omega-copper-tab-battery

The Omega PA250i Copper Tab Battery Welding System is capable of welding highly conductive metals such as copper and aluminum. It also comes in a CNC version that is capable of performing all the same tasks with the assistance of a CNC table.

This system brags an all new design and performance. This latest update takes all of the great features from our previous model and adds to it a new motorized weld head adding greater control, precision, and uniformity to every weld. Manufacturers can produce lighter, more compact battery packs without compromising power or capacity.


Features and Benefits

Sunstone Omega PA250i Copper Tab Battery Welding System:

  • Solderless Connections – The metals are fused together at the weld spot for a continuous connection and no voltage drops.
  • Clean Weld Spots – During the welding process, surface contaminants are burned off, allowing for strong, clean welds.
  • Weld Dissimilar Metals – Sunstone Spot Welders can weld any combination of metals, such as Copper to Aluminum.
  • Small Heat Affected Zone – The heat affected zone (HAZ) is very small and very localized to ensure no degradation to the battery. The Orion provides enough energy to make the weld without affecting the integrity of the cell.


One of the biggest challenges when welding EV Batteries is finding a welder capable of welding highly conductive metals such as copper and aluminum. Inside a lithium-ion battery are various copper and/or aluminum components that carry the electrical current (such as buss bars). These components are commonly joined to either similar or dissimilar materials to facilitate the electric current. If the joint is not made properly, there is a potential for voltage drops due to the resistance between the two pieces.

Regardless of the specific requirements of a particular application, our experts have developed multiple welding solutions for welding EV Battery cells and packs.

What are you welding today? Call or text us at +1-801-658-0015.



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  • Omega PA250i Welding System

    Maximum Power!
    The most powerful Sunstone pulse arc welder delivers 250 joules of energy with precision and accuracy.

    When your production needs require more welding power, turn to Sunstone’s Omega PA250i Welding System, where maximum digital energy control is combined with maximum energy availability. With 250 joules of power your welding capabilities are greatly increased. Available in three different configurations, the PA250i fits any production floor: In your shop, in an automated production line, or anywhere in between.

    Datasheet

    • $0.00
  • The Scout
    • $4,500.00