Custom BMS Connection Tabs
Replace messy wires with precision Laser Cut Nickel Voltage Sense Leads. Engineered for direct PCB soldering and robust spot welding. Eliminate wiring errors and reduce assembly time.
Stop Using "Spaghetti" Wiring
Traditional battery balancing involves soldering individual wires to nickel strips. This is labor-intensive, prone to vibration failure, and messy. Integrated BMS Tabs are the professional solution.
Direct PCB Mount
Our tabs are designed to slot directly into your BMS PCB through-holes or solder pads. This eliminates the need for intermediate wires, reducing resistance and failure points.
Precision Geometry
Using Laser Cutting, we create tabs that reach exactly from the cell terminal to the PCB pad. No slack, no tension, just a perfect mechanical fit.
Vibration Resistance
Rigid nickel tabs vibrate with the battery pack. Unlike flexible wires that can fatigue and snap at the solder joint, nickel tabs provide a structural current path.
Common BMS Tab Geometries
We manufacture custom nickel strips in any 2D shape to fit your specific BMS layout. We also offer secondary CNC Bending for 3D connections.
Used when the BMS is mounted on the side of the battery pack. The tab extends from the cell and turns 90 degrees (flat) to reach the board.
3D Formed. Essential when the BMS sits physically higher than the battery cells. The Z-bend provides stress relief and height clearance.
The end of the nickel strip is laser-cut into narrow “pins” to fit into PCB through-holes, or “forks” to slide under screw terminals.
Engineering for Soldering & Welding
Connecting a metal strip to both a chemical battery and a sensitive circuit board requires careful material selection.
Thermal Management
Soldering to a large nickel strip can be difficult because nickel acts as a heat sink. We can laser-cut "Thermal Relief" patterns (narrow necks) near the solder pad. This prevents the heat from wicking away too fast, ensuring a perfect solder joint without overheating the battery cell.
Material Options
- Pure Nickel N6: The standard. Excellent spot weldability and good solderability with standard flux.
- Nickel-Plated Copper: For high-current balancing (>5A). Copper core moves heat and current efficiently; nickel plating allows spot welding.
- Tin-Plated Nickel: Custom order. Tin plating makes soldering to the PCB even faster and more reliable.
| Parameter | Standard Spec | Custom Capability |
|---|---|---|
| Thickness | 0.10mm – 0.20mm | 0.05mm – 0.50mm |
| Min. Pin Width | 0.5mm | 0.2mm (Micro Laser) |
| Dimensional Tolerance | ±0.05mm | ±0.02mm |
| Bending Angle | 90° ± 1° | Custom Angles / Z-Height |
| Plating | None (Pure Nickel) | Tin (Sn), Gold (Au) Flash |
Where Custom Tabs Are Used
Power Tool Packs
Smart BMS
Medical Devices
E-Mobility
Yes, Pure Nickel (N6) has excellent solderability. Use a standard rosin-core solder and a soldering iron set to approx 350-400°C. Because nickel conducts heat away, we recommend designing thermal relief tabs to make soldering easier and safer for the battery.
Tabs provide a structural connection that is more resistant to vibration failure than stranded wire solder joints. They also reduce pack volume (lower profile) and eliminate the risk of "wire spaghetti" causing short circuits during assembly.
Not for flat shapes! We use Laser Cutting for flat geometry, which requires zero tooling investment. For 3D shapes (Z-bends), we use CNC bending machines for small batches, or stamping dies for mass production.
Yes. We can apply Kapton Tape or stick-on barley paper insulation to specific areas of the tab to prevent shorting against adjacent cells. We also offer powder coating for larger busbars.
Our fiber laser can cut features as narrow as 0.2mm. However, for structural stability, we recommend a minimum strip width of 1.0mm - 2.0mm for any part carrying current.
Simplify Your BMS Integration
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