{"id":2075,"date":"2026-06-28T21:25:42","date_gmt":"2026-06-28T13:25:42","guid":{"rendered":"https:\/\/metalstampingparts.ltd\/nickel-strip-stamping-guide\/"},"modified":"2026-06-28T21:25:43","modified_gmt":"2026-06-28T13:25:43","slug":"nickel-strip-stamping-guide","status":"publish","type":"page","link":"https:\/\/metalstampingparts.ltd\/fil\/nickel-strip-stamping-guide\/","title":{"rendered":"Nickel Strip Stamping Guide"},"content":{"rendered":"<p><strong>Short answer:<\/strong> stamped nickel strips are thin conductive strips used as battery pack interconnects, welding tabs, and busbar links in lithium-ion battery assemblies. They are available as pure nickel, nickel-plated steel, or nickel-clad copper. The main RFQ factors are material type, conductivity, thickness, burr condition, weld surface preparation, and packaging for automated assembly.<\/p>\n<p>This guide is for battery pack designers, procurement teams, and cell manufacturers who need to specify stamped nickel strips for spot-welded or soldered battery connections. Small differences in material purity, strip width, thickness, and edge quality affect weld consistency, electrical resistance, and pack-level reliability.<\/p>\n<p>Send your strip drawing, material specification, thickness, width, and welding requirements through the <a href=\"\/fil\/contact\/\">RFQ form<\/a>. For related battery parts, see <a href=\"\/fil\/ev-battery-stamping-parts-busbars\/\">EV battery stamping parts and busbars<\/a> and the <a href=\"\/fil\/battery-contact-plate-stamping-guide\/\">battery contact plate stamping guide<\/a>.<\/p>\n<h2>Nickel strip material options<\/h2>\n<table class=\"msp-content-table\">\n<thead>\n<tr>\n<th>Material type<\/th>\n<th>Conductivity<\/th>\n<th>Cost<\/th>\n<th>Typical use<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Pure nickel 200\/201<\/td>\n<td>~25% IACS<\/td>\n<td>Highest<\/td>\n<td>High-reliability battery packs, medical, aerospace<\/td>\n<\/tr>\n<tr>\n<td>Nickel-plated steel<\/td>\n<td>~10-15% IACS<\/td>\n<td>Lowest<\/td>\n<td>Consumer power tools, e-bikes, hobby packs<\/td>\n<\/tr>\n<tr>\n<td>Nickel-clad copper<\/td>\n<td>~60% IACS<\/td>\n<td>Moderate<\/td>\n<td>High-current packs, EV modules, power walls<\/td>\n<\/tr>\n<tr>\n<td>Nickel-plated copper<\/td>\n<td>~80% IACS<\/td>\n<td>Moderate<\/td>\n<td>High-current, cost-sensitive applications<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Pure nickel has lower conductivity than copper but better corrosion resistance and easier spot welding to steel cell cans. Nickel-plated steel is cheaper but has higher resistance, which causes more heat during discharge. For high-current packs, nickel-clad or nickel-plated copper provides a better balance of weldability and conductivity. For more on battery-related stampings, see the <a href=\"\/fil\/ev-battery-stamping-parts\/\">EV battery stamping parts<\/a> overview.<\/p>\n<h2>Strip dimensions and tolerances<\/h2>\n<p>Typical nickel strip dimensions vary by pack design and cell type:<\/p>\n<ul>\n<li>Thickness: 0.1 mm to 0.5 mm for common battery packs. 0.15 mm and 0.2 mm are the most common thicknesses for 18650 and 21700 cell interconnects.<\/li>\n<li>Width: 5 mm to 50 mm depending on current and pack layout. Wider strips carry more current but are harder to spot weld reliably due to shunting.<\/li>\n<li>Length: cut to individual tab length, or supplied as continuous coil for automated assembly.<\/li>\n<li>Tolerance on thickness: \u00b10.01 mm for precision, \u00b10.02 mm standard.<\/li>\n<li>Tolerance on width: \u00b10.10 mm for blanked strips, \u00b10.20 mm for slit coil.<\/li>\n<\/ul>\n<p>For precision thin-part tolerances, see <a href=\"\/fil\/precision-small-metal-stamping-electronics\/\">precision small metal stamping for electronics<\/a>.<\/p>\n<h2>Edge quality and burr<\/h2>\n<p>Nickel strip edges should be clean and burr-free on the weld side. Burr on the weld surface creates inconsistent current paths during resistance spot welding, leading to weak welds, expulsion, or electrode sticking. For stamped strips, specify burr on one side (typically the non-weld side) and a maximum burr height of 0.03 mm.<\/p>\n<p>For high-volume automated welding, consider deburred or edge-conditioned strips. Progressive stamping with precision clearance produces the cleanest edges. For related edge quality standards, see <a href=\"\/fil\/metal-stamping-tolerances-guide\/\">metal stamping tolerances guide<\/a>.<\/p>\n<h2>Weld surface preparation<\/h2>\n<p>The nickel strip surface must be clean and free of oil, oxide, or contaminants for consistent spot welding. Key considerations:<\/p>\n<ul>\n<li>Stampers typically use a small amount of stamping lubricant. Specify low-residue or evaporative lubricant if the strip will be welded without cleaning.<\/li>\n<li>For nickel-plated steel strips, the plating thickness and uniformity affect weld consistency. Too thick plating can cause high initial contact resistance, while thin spots may create inconsistent nugget formation.<\/li>\n<li>For nickel-clad copper, the cladding layer must be continuous across the weld zone. Any exposed copper corrodes differently and changes the weld schedule.<\/li>\n<li>Specify surface roughness if the welding process requires a specific contact resistance range.<\/li>\n<\/ul>\n<p>For material surface guidance, see <a href=\"\/fil\/nickel-strip-stamping-guide\/\">nickel strip stamping guide<\/a> and the <a href=\"\/fil\/compare-metal-stamping-quotes\/\">compare metal stamping quotes guide<\/a>.<\/p>\n<h2>Packaging for automated assembly<\/h2>\n<p>Nickel strips for automated battery assembly are typically supplied in one of these forms:<\/p>\n<ul>\n<li><strong>Coil \/ reel-to-reel<\/strong> \u2014 continuous strip wound on reels for high-volume automated welding lines. Reel width, inner diameter, outer diameter, and splice frequency must be specified.<\/li>\n<li><strong>Cut-to-length strips<\/strong> \u2014 individual strips cut to a specific length, supplied in trays or tubes for semi-automated or manual assembly.<\/li>\n<li><strong>Stamped tab-on-strip<\/strong> \u2014 pre-formed strips with weld tabs and bridge features for specific cell spacings. The tabs may include narrowed sections for controlled weld current shunting.<\/li>\n<li><strong>Tape-and-reel<\/strong> \u2014 for pick-and-place assembly of individual small tabs.<\/li>\n<\/ul>\n<p>Each packaging method affects tooling, unit price, and assembly speed. Discuss with your stamper the best packaging format for your line. For more on packing requirements, see <a href=\"\/fil\/metal-stamping-packaging-shipping-guide\/\">metal stamping packaging and shipping guide<\/a>.<\/p>\n<h2>Design considerations for nickel strips<\/h2>\n<p><strong>Strip pattern.<\/strong> The most common nickel strip design is a ladder-type pattern with weld tabs at each cell position connected by continuous strips. The tab width, tab pitch, and bridge width must match the cell layout and welding electrode shape. Tab width typically ranges from 4 mm to 10 mm, with a narrowed section near the bridge to reduce weld current shunting.<\/p>\n<p><strong>Fuse features.<\/strong> Planned narrow sections or slots in the nickel strip can act as fuses, protecting individual cells from overcurrent without external fuses. This is common in high-series-count battery packs. If fuse features are required, the geometry must be designed to open at a specific current and time, and confirmed through testing.<\/p>\n<p><strong>Fold or formed tabs.<\/strong> For packs where the strip must transition between cell rows or layers, the strip may require formed bends or offset features. These formed features need corner radii to avoid stress concentration and cracking in nickel or nickel-plated materials.<\/p>\n<p>For more on forming and DFM, see <a href=\"\/fil\/metal-stamping-dfm-review-before-tooling\/\">metal stamping DFM review before tooling<\/a>.<\/p>\n<h2>RFQ checklist for nickel strips<\/h2>\n<ul>\n<li>Drawing with strip dimensions, tab pattern, tab pitch, bridge width, and any formed features.<\/li>\n<li>Material: pure nickel (grade), nickel-plated steel (base steel grade + plating thickness), nickel-clad copper (clad ratio), or nickel-plated copper.<\/li>\n<li>Thickness and width tolerance requirements.<\/li>\n<li>Annual volume, order quantity, and delivery schedule.<\/li>\n<li>Weld method: resistance spot welding, ultrasonic welding, laser welding, or soldering.<\/li>\n<li>Burr direction and max burr height.<\/li>\n<li>Packaging: coil, cut strip, tape-and-reel. For coil, specify inner\/outer diameter and max splice count.<\/li>\n<li>Quality: surface inspection, dimensional check frequency, material certificate requirement.<\/li>\n<li>Fuse requirements if applicable: target current and response time.<\/li>\n<\/ul>\n<p>Submit your nickel strip drawing through the <a href=\"\/fil\/contact\/\">RFQ form<\/a>. For broader RFQ preparation, see the <a href=\"\/fil\/metal-stamping-rfq-checklist\/\">metal stamping RFQ checklist<\/a>.<\/p>\n<h2>FAQ<\/h2>\n<div itemscope=\"\" itemtype=\"https:\/\/schema.org\/FAQPage\">\n<div itemscope=\"\" itemprop=\"mainEntity\" itemtype=\"https:\/\/schema.org\/Question\">\n<h3 itemprop=\"name\">Is pure nickel or nickel-plated steel better for battery packs?<\/h3>\n<div itemscope=\"\" itemprop=\"acceptedAnswer\" itemtype=\"https:\/\/schema.org\/Answer\">\n<div itemprop=\"text\">Pure nickel welds more consistently, has better corrosion resistance, and lower resistance per cross-section than nickel-plated steel. Nickel-plated steel is cheaper and may be adequate for low-discharge packs. For high-current or high-reliability packs, use pure nickel or nickel-clad copper.<\/div>\n<\/div>\n<\/div>\n<div itemscope=\"\" itemprop=\"mainEntity\" itemtype=\"https:\/\/schema.org\/Question\">\n<h3 itemprop=\"name\">Can nickel strips include fuse features?<\/h3>\n<div itemscope=\"\" itemprop=\"acceptedAnswer\" itemtype=\"https:\/\/schema.org\/Answer\">\n<div itemprop=\"text\">Yes. Narrow sections, slots, or reduced-thickness zones can be stamped into the strip to act as planned fuse links. Fuse geometry must be designed for the target current and tested, because material thickness, ambient temperature, and heat dissipation change the actual fusing current.<\/div>\n<\/div>\n<\/div>\n<div itemscope=\"\" itemprop=\"mainEntity\" itemtype=\"https:\/\/schema.org\/Question\">\n<h3 itemprop=\"name\">What is the typical nickel strip thickness for 18650 battery packs?<\/h3>\n<div itemscope=\"\" itemprop=\"acceptedAnswer\" itemtype=\"https:\/\/schema.org\/Answer\">\n<div itemprop=\"text\">0.15 mm and 0.2 mm are the most common thicknesses for 18650 cell interconnects using nickel strip. For nickel-plated steel, 0.15 mm is typical. For pure nickel, 0.2 mm is common. Thicker strips reduce resistance but may need higher weld energy and risk shunting through adjacent welds.<\/div>\n<\/div>\n<\/div>\n<div itemscope=\"\" itemprop=\"mainEntity\" itemtype=\"https:\/\/schema.org\/Question\">\n<h3 itemprop=\"name\">Do nickel strips need surface treatment before welding?<\/h3>\n<div itemscope=\"\" itemprop=\"acceptedAnswer\" itemtype=\"https:\/\/schema.org\/Answer\">\n<div itemprop=\"text\">Nickel and nickel-plated strips generally do not need surface treatment if stored clean and dry. If stamping lubricant is used, specify low-residue lubricant. For nickel-clad copper, the cladding provides a weld-ready surface. If the strip shows visible oxidation or contamination, a cleaning step before welding improves consistency.<\/div>\n<\/div>\n<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>Short answer: stamped nickel strips are thin conductive strips used as battery pack interconnects, welding tabs, and busbar links in [&hellip;]<\/p>\n","protected":false},"author":0,"featured_media":1855,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"class_list":["post-2075","page","type-page","status-publish","has-post-thumbnail","hentry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Nickel Strip Stamping Guide<\/title>\n<meta name=\"description\" content=\"Guide to stamped nickel strips for battery pack interconnects, busbars, and welding tabs. 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