Precision Stamping & Mass Production
The ultimate solution for scaling up. We utilize high-speed Progressive Die Stamping to produce millions of identical nickel tabs and busbars with micron-level precision and the lowest possible unit cost.
The Economics of Scale
Laser cutting is great for prototypes, but it's too slow for mass production. Stamping requires an upfront investment in a mold (tooling), but the speed is unmatched. See where the break-even point lies for your project.
Break-Even Analysis
Once you move past the prototyping phase, the cost per part becomes critical. A stamping press can produce 200-400 parts per minute, whereas a laser might take 10-30 seconds per part.
For orders over 5,000 to 10,000 pieces, the cost savings from stamping usually outweigh the initial tooling fee. Additionally, the consistency of a hard tool ensures that the 1st part and the 1,000,000th part are identical.
High Speed: Up to 400 strokes/min.
Low Waste: Advanced nesting reduces scrap.
| Volume (Pcs) | Laser Cutting Cost | Stamping Cost |
|---|---|---|
| 100 | Low | Very High (Tooling cost) |
| 1,000 | Medium | High |
| 5,000 | High | Break-Even Point |
| 100,000+ | Prohibitive | Extremely Low |
Beyond Flat Shapes: The 3D Advantage
Unlike laser cutting which is strictly 2D, precision stamping allows for metal forming. This is crucial for modern battery pack designs that require complex geometry for BMS connections and thermal management.
3D Bending & Forming
We can create 90° bends, Z-bends, and complex folds in a single pass. Essential for connecting battery modules to BMS boards or navigating around cooling channels without manual bending.
Dimples & Projections
We stamp raised "dimples" onto the nickel strip. These projections concentrate the current during spot welding, ensuring a stronger, deeper weld nugget with less energy.
Coining & Chamfering
We can compress the metal to create chamfered edges (eliminating sharp burrs completely) or coined sections to strengthen specific areas of the busbar.
Tolerances
Standard: ±0.05mm Precision: ±0.02mm Maintained over million-cycle runs.
Press Capacity
Range: 25 Tons to 110 Tons. Capable of stamping up to 2.0mm thick Copper/Nickel.
Die Types
Progressive Dies (Multi-stage) Compound Dies (Simple parts) Deep Draw Dies
Quality (CPK)
Real-time vision inspection. CPK > 1.33 assured for critical dimensions.
In-House Tooling Center
Many factories outsource their mold making, leading to delays and communication errors. At CustomNickelStrips, we design, build, and maintain all our stamping dies in-house.
Faster Lead Times
We can go from CAD design to T1 sample (first trial) in as little as 10-14 days, compared to the industry standard of 4 weeks.
Lifetime Maintenance
If you pay for the mold removal, we will maintain it for you forever. If a punch wears out after 500k hits, we replace it immediately at no cost to you. Your production never stalls.
Design Security
Your proprietary battery tab designs are never left outside our facility. We guarantee IP protection.
It varies based on complexity and size. A simple single-stage die might cost $300-$500. A complex multi-stage progressive die for intricate shapes usually ranges from $1,000 to $3,000. However, this is a one-time fee.
Yes. If you pay the tooling fee, the mold belongs to you. We store and maintain it for free for the lifetime of your project. If you ever decide to move production (which we hope you won't!), you can take the mold with you.
Yes. Stamping is actually better for composite materials than laser cutting because it doesn't generate heat that could separate the layers. We have extensive experience handling soft copper alloys.
Technically, we can stamp 1 piece, but the setup time (loading the coil, aligning the die) makes it expensive. We recommend a Minimum Order Quantity (MOQ) of 5,000 to 10,000 pieces to get a competitive unit price.
Typically 12-15 working days for mold design and fabrication. Once the mold is verified, production lead time is extremely fast (e.g., 50k pieces in 2-3 days).
Scale Up Your Production
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