Battery
7 settings
adjustable: actuator, delay, energy, mode, pulse width, polarity, capacitance
No filler
heat and pressure bond
Automatable
integrates with production lines
Dissimilar
metals and fine wires
Chapter 01 / 05
Battery Welding Solutions with Percussion Welder
Unlock the future of battery manufacturing with Percussion Welder's advanced welding technology. Our system provides precise, strong, and durable welds for battery pack assembly and battery tab welding, ensuring exceptional performance and reliability. Perfect for high-volume production, our customizable solutions meet the specific needs of the automotive industry and beyond.
Chapter 02 / 05
Exceptional Battery Welding Process
Many industries rely on batteries, with the need to weld various metals to build cells and to fuse together to connect batteries, wires, and components. Percussion Welder offers the ideal solution for battery pack assembly welding and battery tab welding.
In the past, the battery welding process has been difficult, with challenges in joining dissimilar materials, completing the fine welds required for wires, and in producing quality welds that are strong, durable, and precise. Today, the automotive industry utilizes our percussion welding technology and systems to address these issues with battery welding that increases safety and the proper functioning of components.
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Equipment and sample welds
Lab equipment and weld samples.
Chapter 03 / 05
Customized Battery Welding Solutions
Our Percussion Welder system offers solutions that address the specific concerns of the automotive industry when it comes to welding batteries, sensors, light bulbs, and other electronic parts and components found in all types of vehicles.
Our battery tab welding system and percussion welding process allow for high-volume welding without compromising weld quality or strength. Our Percussion Welder system can be fully integrated with automated systems, ensuring manufacturing rates are maintained even in a high production battery manufacturing process.
Percussion welding uses both heat and pressure to create welds for battery components. A small gap between the two parts allows the generation of an electrical arc that melts the materials, with percussion rapidly pushing the molten materials together for a precise, complete, and filler-free bond. It can be adjusted to meet your specific production requirements.
To discuss the use of our Percussion Welder system for your battery pack manufacturer needs, send us a message online or call us today at 303-536-7838.
Chapter 04 / 05
Advanced Battery Welding Technology
At Percussion Welder, we leverage cutting-edge technology to revolutionize the battery welding process. Our innovative system combines heat and pressure to create robust, precise welds without the need for filler materials. This method not only ensures uniform weld strength but also enhances the overall durability and reliability of battery components. Our technology is designed to address the unique challenges of joining dissimilar metals, making it ideal for a wide range of applications in the battery manufacturing industry.
Our Percussion Welder system can be fully integrated with automated production lines, allowing for high-volume manufacturing without sacrificing quality. The ability to customize settings such as actuator control, delay, weld energy, mode, pulse width, polarity, and capacitance ensures that each weld meets your exact specifications. This flexibility makes our system an indispensable tool for producing advanced battery packs, sensors, and electronic components, ultimately contributing to the efficiency and safety of modern vehicles and other electronic devices.
Chapter 05 / 05
Why Choose Percussion Welding in Battery production ?
High Precision and Strength
Percussion welding ensures precise, strong welds that are essential for the reliability and safety of battery components.
Efficient and High-Volume Production
Our welding system supports high-volume production without compromising on weld quality, making it ideal for large-scale battery manufacturing.
Integration with Automated Systems
Fully compatible with automated systems, our Percussion Welder system enhances production efficiency and consistency.
Customizable Solutions
We offer tailored solutions to meet specific production requirements, ensuring optimal performance and quality for every application.
Where to next
Battery Tab Welding: The Complete Guide for Electronics Manufacturing
Complete guide to battery tab welding: copper-to-nickel, aluminum-to-copper, nickel-to-steel connections. Percussion welding attaches tabs in under 3ms without heat damage to cells.
Open →Battery Tab Welding: Percussion vs. Spot Welding
Percussion vs. resistance spot welding for battery tabs: HAZ, cycle time, dissimilar metal capability, and electrode wear compared. Which method for copper-nickel and aluminum tabs?
Open →Optimizing Battery Pack Assembly with Percussion Welding
When it comes to battery pack assembly, precision and reliability are paramount. Ensuring that battery components are securely joined, durable, and free from defects is essential for both safety and functionality. In
Open →Parameter Finder
Open →FAQ
What battery work does this cover?
Battery pack assembly and battery tab welding, including welding cells together and connecting batteries, wires and components.
How is the weld made?
A small gap between two parts allows an electrical arc that melts the materials. Percussion then pushes the molten material together for a complete, filler-free bond.
What can be adjusted?
Actuator control, delay, weld energy, mode, pulse width, polarity and capacitance, so each weld can match your specification.
What problems does it address?
Battery welding has been difficult because of joining dissimilar materials, completing the fine welds wires require, and producing welds that are strong, durable and precise. Percussion welding addresses those problems.
Can it run on an automated line?
Yes. It can be fully integrated with automated systems for high-volume production without compromising weld quality or strength.
Which tab materials and thicknesses work?
That depends on your tab and cell. Our lab database holds 131 weld schedules across 33 materials and 68 pairs, which are starting points rather than guarantees. Send us your tab and cell material and thickness, or call 303-536-7838, and we'll run a trial weld.
Still have a question? Tell us your weld challenge and an engineer will reply.
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Send the tab material, thickness and cell format, and we will run a trial weld in Denver.
Prefer to talk? Book a demo or call 303-536-7838