Map the connection level

Cell tabs, module busbars, pack busbars, current collectors, and sensor connections have different material requirements.

  • Cell tab: welding compatibility and surface behavior
  • Module busbar: current, thermal rise and mechanical load
  • Pack busbar: insulation, assembly, and service safety
  • Current collector: foil thickness, surface and roll quality

Choose material by joining method

Laser welding, ultrasonic welding, resistance welding, soldering, and mechanical fastening all place different demands on surface and material stack.

  • Copper supports high conductivity but may require process tuning
  • Aluminum reduces weight but needs compatible joining
  • Nickel and nickel surfaces support selected welding and corrosion requirements
  • Clad materials can combine surface and core properties

Build traceability into the RFQ

Battery applications often require batch traceability, certificates, dimensional reports, and stable packaging to reduce downstream risk.

  • Ask for COA and batch labels
  • Define burr and edge requirements
  • Include drawing revision and inspection standard
  • Confirm sample and PPAP-like approval process when needed

FAQ

What material is best for battery tabs?

It depends on cell chemistry and joining method. Common choices include copper, aluminum, nickel, nickel plated copper and nickel clad copper.

Why use clad materials in batteries?

Clad materials can combine surface compatibility, corrosion behavior, and conductivity in one material stack.

Can Raytron support custom battery connection materials?

Yes. Raytron supports custom strip, foil, flat wire, and clad metal materials for battery and EV applications.