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Omega PA250i Welding System

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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.

The Case for Copper Brochure

Battery Welding Systems Datasheet

Omega Battery Welder Datasheet

Omega PA250i User Manual

Battery Welding Best Practices

Omega PA250i Press Release

  • Sunstone Circle Protection Plan Subscription

    The best protection your investment has ever seen!


The Case for Copper

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.  The Omega PA250i welder is capable of overcoming some of these challenges, thus opening new doors in the world of EV battery welding, specifically by being able to weld copper tabs to battery cans.


Boost Efficiency

With copper tabs, power cell efficiency significantly improves. And when the customer experience is all about battery performance, copper is king!

1.18 x 107σ
5.96 x 10 7σ
1.68 x 10-8ρ
8.50 x 10-8ρ

Save Money

Copper tabs will connect your power cells more efficiently and do it for more than half the price compared to some nickel.

as of OCT 2020
USD $3.09/lbs
USD $7.16/lbs

Weld Confidently

With copper, attach a thicker tab for a larger spot size and improved peel strength. Plus, the heat affected zone is small, quick and won’t damage the power cell’s internal components.

Nugget Area5.06mm2
Nugget Diameter2.54mm
Peel Strength10kg/22lbs
Thickness0.010 - 0.020”
0.005 - 0.010”

Sunstone’s Omega PA250i Copper Battery Tab Welder Provides:



Dissimilar Welding CapabilitiesCopper to steel, copper to aluminum, nickel to steel—ideal for battery welding!
3 Available Configurations1) Stylus only
2) Weld head
3) CNC table
250 Ws Max EnergyThe most powerful Sunstone pulse arc micro welder yet!
Weld materials 0.003-.030” (0.075-0.75mm) in thicknessPerfect for attaching copper tabs to power cells
Digital ControlAdjust and control all energy attributes with color touch screen
Visual Waveform GraphsView energy waveforms and histograms
PLC-ReadyWith 5 outputs/2 inputs easily integrates into your production process
CNC CompatibilityAttaches to any CNC table, like the Janome Cartesian Robot, for maximum production levels
127 Remote SchedulesSaves time with access to saved welds
Import/Export Saved WeldsEasily transfer settings to other units
Lock-Out ModePrevent changes to production settings
Alarms and WarningsAvoid time-consuming errors or potentially hazardous conditions
Built-in TrainingHow-to videos always at your fingertips
WiFi Software UpgradesOn-board software is easily maintained


Overview and Applications

The Omega PA250i Copper Tab Battery Welder 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 of the Sunstone Omega PA250i Copper Battery Tab Welder:

  • 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 250i provides enough energy to make the weld without affecting the integrity of the cell.

More About the Omega PA250i Copper Tab Battery Welder System

The Omega PA250i is the perfect copper battery tab welder.  The Omega PA250i has a new design to give superior performance. This newest update takes all of the great features from our previous EV copper tab battery welder, and adds to it a new motorized weld head for greater control, precision, and uniformity to every weld. The power supply has also been upgraded to offer superior control and fine-tunabilty to guarantee the perfect weld can be achieved.  Manufacturers can produce lighter, more compact, and more efficient battery packs without compromising power or capacity.

The Omega PA250i in Action

Customer Spotlight on Vantage Power

The Omega PA250i CNC Version

Sunstone’s Omega PA250i copper battery tab welder also comes in a CNC version that is capable of performing all the same tasks with the assistance of a CNC table. Watch the below video to see it in action.

Do You Need Training?

Sunstone's training team is ready to help you master the Orion 100c for any particular application, like permanent jewelry, Visit our Training Page to learn more.

    • Weight
      37 lbs
    • SKU
  • Micro TIG (Pulse Arc) Welder Specifications
    • Welding Energy Range (Joules)
      0.2-250 Joules
    • Weld Spot Diameter Range
      ≈ 0.1 - 4 mm
    • Display (Touch Screen)
      25 cm
    • Max Weld Speed
      1 weld/0.5 seconds
    • Available Weld Energy Settings
    • High Frequency Agitation Options
    • Save Setting Spaces
    • 5x Microscope Magnification
    • Microscope IR & UV Eye Protection
    • 20+ On-screen Languages
    • Arc Start Technology
    • Tack Mode
    • Basic Screen Metal Presets
    • Adaptive Weld Ignition
    • Dynamic Energy Adjustment
    • Multiple Welding Waveforms
    • Pico Mode

Introducing the Sunstone Circle Protection Plan


For your welder, it's a scary world out there! Welders get dropped, get abused, or just stop working. You have to protect your welder for any unfortunate incident. And the Sunstone Circle Protection Plan is an innovative way to safeguard your welder investment.

The Sunstone Circle is much, much more than an extended warranty. Here's what a small monthly subscription will deliver in peace of mind and exceptional customer service:

Sunstone Circle Protection Plan

Forever Warranty
For as long as your welder is covered by the Sunstone Circle your warranty never expires. You’ll never deal with lifeless warranty extensions, but rather enjoy a forever warranty. And that’s a big circle of protection!

Complimentary Loaner
If you need a loaner unit while your welder is being repaired, we’ll send one. We’re going to do all we can to keep your production levels up. If you’re in the circle, we’ll take care of you!

Free Replacement
Sometimes it makes more sense to simply replace a welder with the newest model rather than make a repair. At Sunstone’s discretion, we’ll send you the newest model to keep your shop happy and healthy!

Free Software Upgrades
When your welder is powered by the latest software improvements your shop becomes more productive and capable. You’ll have access to all software upgrades when you join the Sunstone Circle!

Complimentary Shipping
Should your Sunstone welder ever need repair, we’ll cover the shipping costs for ground service within the United States. If you need it faster, simply pay the difference. Need it shipped internationally? Give us a call!

Expedited Customer Service
At Sunstone every customer is a VIP, but when you’re part of the circle your request for customer service gets moved to the front of the line. You get extra attention! Just another perk when you subscribe today.

More Valuable Member Benefits!
You’ll receive snazzy Sunstone swag, a subscription to Micro Welding Today magazine, invitations to VIP events, Inside the Circle e-newsletter, and new product trial opportunities. Call now to join the circle!

Learn More!

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We Deliver Worldwide

Shipping Terms

  1. Unless indicated otherwise in the Acknowledgment, Delivery shall be made EXW (Incoterms 2010), Shipping Point, including without limitation, freight, and insurance costs. If no delivery terms are specified on the Acknowledgement, the method of shipping will be at the sole discretion of Seller. Unless directed in writing otherwise by Buyer, full invoice value will be declared for all shipments.

We accept the following payment methods:

Return Goods Policy. 

Seller’s products may be returned to Seller for credit within thirty (30) days of the shipment subject to the following conditions.

Sunstone offers a 30-day return policy on all products. Before sending a product back please contact Sunstone to receive an RMA number. The RMA number should appear clearly on the outside of the package. Customers are refunded via check. Please note that a 10% restocking fee will apply to all returns. A 30% restocking fee will apply to all 3rd party products (laser welders, laser engravers, PW - AC Welders, and AVIO products). Additionally, all 3rd party products must be insured when sent back to Sunstone at the buyer’s expense. In some cases, a merchant fee may apply. Equipment damaged by improper use or insufficient shipping precautions will be charged additional fees.

*DADO Laser Welder – No cash refunds available for the dado laser welder. However, The Dado Laser Welder may be returned within 30 days for credit towards another Orion or Sunstone product.

*Argon tanks have a $35 restocking fee, the tank must be emptied and left open with the protective cap put in place. All hazardous material and compressed gas stickers need to be removed from the packaging as the empty cylinder is not hazardous and doesn't contain compressed gas.

*Refunds will not be issued for services that have already been rendered such as shipping, calibration, or trainings.

  • Orion Micro TIG Welding Electrodes
    • $75.00
  • Premium Argon Gas Regulator
    • $149.00
  • Battery Welding Electrodes
    • $35.00
  • Tungsten Micro Welding Electrodes
    • $30.00
  • Dual Probe Handpiece
    • $175.00

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