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.

The combination of the electrical arc weld between the two metals and the percussion used to force the molten materials together creates a precise weld that eliminates the need for filler metals. The micro weld is uniform around the two pieces, which leads to exceptional weld strength, even with two different metals.
858 Front Panel
858 Front Panel

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.

Adjustments & Features of the
Model 858 Front Panel

858 Front Panel

Actuator: The actuator setting
controls the charging voltage of the
capacitors that energize the
electromagnetic actuators. The range is
0 to 150 volts. The actuators move
the weldments together
during the welding process.

Delay: The delay is 0.5 to 5.0
milliseconds between actuator
initiation and discharge
of weld energy.

Weld: The weld energy voltage
control determines the charging
voltage applied to the
weld capacitors. The range
is 0 to 150 volts.

Mode: There are two mode settings,
regular and heavy-duty.
Heavy Duty adds an additional
bank of capacitors to
the weld output.

Pulse: The long / short pulse
width switch provides the
operator with pulse
width control. A long pulse
delivers less peak energy
for a long time
than a short pulse.

Polarity: Controls the direction of
weld energy electron flow.
The direction of electron flow
affects the amount of
heat applied to each weldment.

Capacitance: This setting controls the
amount of capacitance in the
weld output circuit. There
are three capacitance
ranges labeled 1, 2 and 3.


Operation so simple and intuitive on model 858, we can show you how to use it in less than 60 seconds

If you’re like us, sometimes a picture (or video) is worth a thousand words. Watch our 60-second video showing you step-by-step how easy Percussion Welder 726 Bench fixture is to operate.

Follow us on Instagram

Follow us on Instagram

For more demos, slow-mo’s, and closeups of the action.

Let's Talk

No matter what your micro-welding challenge is, the Percussion Welder team at MTI Microwelding is available to offer guidance, answer questions, and even run live, in-person tests using our equipment.

See Potential? Let's Discuss Your Application

After exploring the advantages of percussion welding for small components, are you eager to see how it could benefit your specific application? Schedule a 15-minute consultation with our experts to discuss your project and explore the possibilities!