Custom Laser Cut Nickel Tabs
Turn your CAD designs into physical battery interconnects in 24 hours. We utilize high-precision Fiber Lasers to cut Pure Nickel and Copper composite strips with zero tooling costs.
Why Choose Laser Cutting?
Traditional stamping requires expensive molds and weeks of lead time. Laser cutting is digital, flexible, and instant. It is the ultimate solution for R&D, prototyping, and small-to-medium production runs.
Zero Tooling Fees
Forget about paying $500-$2000 for a stamping die. Laser cutting is mold-free. You pay only for the material and the laser time. Perfect for testing 10 iterations of a design.
Rapid Turnaround
Speed to market matters. Once we verify your CAD file, production starts immediately. We typically ship prototype orders within 24-48 hours.
Complex Geometries
Laser can cut shapes that stamping cannot, such as intricate fuse-link patterns, ultra-narrow slots, and variable spacing for non-standard battery packs.
Fiber Laser + Nitrogen Shielding
Not all laser cutting is suitable for battery tabs. Standard CO2 lasers can overheat the nickel, causing warping and oxidation (black edges) that ruin spot weld conductivity.
We use state-of-the-art Fiber Optic Lasers combined with High-Pressure Nitrogen Assist Gas.
Cold Cutting Effect
The fiber laser focuses energy into a micron-sized spot, vaporizing the metal instantly. The heat-affected zone (HAZ) is microscopic.
Oxide-Free Edges
Nitrogen gas blows away the molten metal and shields the cut from oxygen. The result is a bright, clean, silver edge that requires no post-processing cleaning.
Capabilities & Tolerances
Our machines are calibrated for the specific metallurgy of Pure Nickel N6 and Nickel-Plated Steel.
| Parameter | Specification Capability |
|---|---|
| Materials Supported | Pure Nickel (N6), Nickel Plated Steel, Copper-Nickel Composite |
| Thickness Range | 0.05mm to 0.50mm (Nickel) / Up to 1.0mm (Copper Composite) |
| Max Sheet Size | 600mm x 600mm (Larger sizes available upon request) |
| Dimensional Tolerance | ±0.03mm (High Precision Mode) |
| Minimum Hole Diameter | 0.2mm (Depends on material thickness) |
| Burr Height | < 0.01mm (Virtually Burr-Free) |
Design for Manufacturing (DFM) Guide
To ensure the fastest turnaround and lowest cost for your custom nickel strips, follow these engineering guidelines when preparing your CAD files.
File Formats
- Preferred: .DXF, .DWG (AutoCAD)
- Acceptable: .AI, .PDF (Vector), .STEP
- Scale: Always draw in 1:1 scale (mm).
Critical Design Rules
- Minimum Bridge Width: Avoid making connecting strips narrower than the material thickness. For 0.15mm nickel, keep bridges >1mm for structural integrity.
- Spot Weld Area: Leave at least 6mm x 6mm clear area for spot welding probes to make contact.
- Fuse Links: If designing built-in fuses, ensure the neck width is calculated for your specific burst current.
- Sharp Corners: Laser can cut sharp 90° corners, but we recommend adding a 0.5mm radius (fillet) to internal corners to reduce stress concentration.
Process Comparison: When to choose Laser?
Chemical Etching
Great for ultra-thin foils, but slow and involves hazardous chemicals. Expensive setup for small batches.Cost: High | Speed: Slow
Fiber Laser Cutting
The winner for flexibility. Zero tooling cost, micron precision, and instant setup. Best for R&D and Pilot Runs.Cost: Low | Speed: Fast
Die Stamping
Unbeatable unit price for millions of parts, but requires weeks to build a mold. Inflexible if design changes.Cost: Lowest (High Vol) | Speed: Fastest
Yes. For laser cutting, we can produce a single prototype piece. However, the unit price drops significantly as you order more (e.g., 100 pcs vs 1 pc) due to machine setup time distribution.
Yes. Our fiber lasers are capable of cutting highly reflective materials like copper and our specialized sandwich composite strips without delamination.
Laser cut parts are delivered as individual flat pieces. We pack them in rigid trays or vacuum-sealed stacks to ensure they remain perfectly flat for your automated or manual assembly.
We use advanced nesting software to maximize material utilization from the nickel sheet. This reduces waste and keeps your per-unit cost as low as possible.
Yes. We have secondary CNC bending capabilities. We can laser cut the flat pattern and then precision bend tabs to 90 degrees or other angles for BMS connections. Note: Bending adds a small labor cost.
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