Request Info

Tell Us About Your Welding Project







Battery Nickel Tabs

Battery Nickel Tabs

Weld Nickel Battery Tabs

Including Battery Pack Rebuilding, Battery Pack Assembly, Tab Connections, and Custom Pack Manufacturing using cylindrical cells and battery cans. Learn about our new Copper Tab welding capabilities!

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




Battery Tab Spot Welding Systems

Recently, more and more people are looking for a custom built and/or rebuilt battery packs using a battery spot welder. The reason for the increase in interest comes from the ability to get a higher quality battery pack for less money. By providing customers with higher grade cells at lower than retail prices, it is easy to gain loyal, life-long customers while still making a significant profit.battery tab spot welder

Building battery packs consist of welding thin nickel tabs from one battery cell to another with a battery spot welder. Sunstone ‘s CD400DP (Capacitive Discharge / 400 watts second/dual pulse) spot welders combined with Sunstone’s WH2125 (Parallel weld head / with 0.125″ Copper Electrodes) are the perfect battery tab spot welding systems for battery pack rebuilding, assembly and manufacturing.

The CD400DP’s dual pulse feature provides strong, clean, repetitive welds. The first pulse heats the weld surface to eliminate contaminants and to seat the welding electrode tips. The second pulse then performs a strong spot weld. This process is designed specifically for battery pack spot welding.

Battery Welding Applications:

  • Battery Pack Production
  • Custom Battery Packs
  • Battery Pack Re-building
  • Battery Cell Tabbing
  • Weld Alkaline, Ni-Cd, NiMH,     Lithium-Ion Cell Types, etc.



Battery Welding Systems:

Sunstone provides several package deals for battery pack manufacturers. As mentioned above the most popular battery spot welder package consists of theCD400DP and the WH2125.

  • CD400DP and WH2125 – The 400-watt second spot welders provide the ability to fine-tune the weld energy for welding nickel tabs to batteries while also providing enough power to weld thicker terminal tabs. The WH2125 weld head provides fine control of weld pressure ranging from 3 to 15 lbs. Each electrode’s pressure setting can be adjusted individually. The WH2125 is available for either pneumatic or manual operation.
  • CD400DP and DPHP– The 400-watt second spot welders provide the ability to fine-tune the weld energy for welding nickel tabs to batteries while also providing enough power to weld thicker terminal tabs. The DPHP hand welding attachment is a simple solution for battery pack welding that does not require fine control of weld pressure or speed. 
  • CD200DP and DPHP– The 200-watt second spot welders provide the ability to fine-tune the weld energy for welding nickel tabs to batteries. The DPHP hand welding attachment is a simple solution for battery pack welding that does not require fine control of weld pressure or speed.



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

Items: 14 of 4
  • Micro Resistance - Dual Pulse CD Spot Welders

    The dual pulse industrial capacitive discharge (CD) spot welder provides a substantially larger amount of weld energy combined with a finer range of power adjustment. As with Sunstone's other spot welders, the CDDP welders produces clean, strong welds. Pulse one heats the weld area to eliminate surface contaminants and seats the welding electrodes. Pulse two then makes a strong, secure weld. Both pulses occur within milli-seconds.

    • $4,830.00
  • Micro Resistance - Advanced Dual Pulse CD Spot Welder

    • Feedback reporting
    • PLC connectivity
    • Full weld head control
    • 200ws, 400ws, or 600ws power
    • Roll spot
    • Custom pulse limits
    • Fast rise time
    • On screen histogram weld data
    • On screen training videos
    • $7,930.00
  • Parallel Weld Head

    Sunstone WH2125A series/parallel, MAC Valve Air-Actuated Weld Head with foot pedal, trigger cable, 1 AWG ..

    • $3,365.00
  • Battery Tab Welding System

    Sunstone's battery tab welding systems will allow you to create your own battery packs using nickel tabs. These systems have been specifically designed and engineered for battery production and have the durability to continue to work for a long lifespan.

    • $0.00