Precision Power: How We Assemble Battery Packs with Micro TIG Welding and Copper Tabs

At Zero Point Energy Labs, every battery pack is a precision-engineered energy system—not just a collection of cells. To ensure peak performance and lasting reliability, we use Micro TIG welding with Sunstone technology, argon shielding gas, and copper-nickel tabs in a meticulously controlled assembly environment.

 

 

Why Micro TIG Welding?

 

We use Micro TIG (Tungsten Inert Gas) welding because it offers:

 

  • Extreme precision – Perfect for welding thin copper-nickel tabs to battery terminals with minimal thermal spread
  • Superior joint strength – Compared to ultrasonic or resistive welding, Micro TIG delivers consistent, high-integrity bonds
  • Clean operation – Minimal spatter and oxidation when combined with argon shielding

 


We trust Sunstone Engineering for our Micro TIG welders—renowned in the industry for their control, reliability, and micro-weld capabilities in battery manufacturing.

 

 

Copper-Nickel Tabs + Argon Shielding = Clean Connections

 

Our use of copper-nickel tabs strikes the ideal balance between conductivity, corrosion resistance, and mechanical integrity. These tabs are:

 

  • Laser-cut for tight dimensional tolerance
  • Pre-cleaned to eliminate contaminants
  • TIG-welded in a localized pattern to minimize thermal stress on cells

 


To prevent oxidation and preserve weld quality, we flood the weld zone with argon gas, shielding the joint from ambient oxygen and moisture. The result: a cleaner, stronger, and more reliable connection.

 

 

Clean Assembly Environment

 

All battery packs are built in a low-dust, anti-static environment. We strictly control particulate matter and moisture to protect sensitive materials and electronics. Our assembly protocols include:

 

  • ESD-safe tools and workstations
  • Nitrile gloves and grounded wrist straps
  • Filtered ventilation to minimize airborne contamination during welding and handling

 

 

 

Safety, Quality & HPPC Power Testing

 

We don’t just build—we verify. Every completed pack goes through multi-point inspection and HPPC (Hybrid Pulse Power Characterization) testing to quantify:

 

  • Available power under real-world load
  • Internal resistance growth under high-current pulses
  • Thermal behavior during operational stress

Additional quality checks include:

  • Weld inspection under magnification
  • Mechanical integrity verification
  • Internal resistance measurements
  • Pack balancing and thermal diagnostics

 

 

 

Built in the USA. Built to Endure.

 

All of our packs are designed, assembled, and tested in the USA, using high-grade, locally sourced materials. We’re not just building energy storage—we’re engineering modular, resilient systems for critical applications. Whether it’s edge-space electronics or robotics, we build to outlast and outperform.

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