Omega PA250i Welding System

When your production needs require more welding power, turn to Sunstone’s Omega PA250i Welding System, where maximum digital energy control is combined with maximum energy availability. With 250 joules of power your welding capabilities are greatly increased. Available in three different configurations, the PA250i fits any production floor: In your shop, in an automated production line, or anywhere in between.

Download Manual



The Case for Copper

One of the biggest challenges when welding EV batteries is finding a welder capable of welding highly conductive metals such as copper and aluminum. Inside a lithium-ion battery are various copper and/or aluminum components that carry the electrical current (such as buss bars). These components are commonly joined to either similar or dissimilar materials to facilitate the electric current. If the joint is not made properly, there is a potential for voltage drops due to the resistance between the two pieces.  The Omega PA250i welder is capable of overcoming some of these challenges, thus opening new doors in the world of EV battery welding, specifically by being able to weld copper tabs to battery cans.


Boost Efficiency

With copper tabs, power cell efficiency significantly improves. And when the customer experience is all about battery performance, copper is king!

1.18 x 107σ
5.96 x 10 7σ
1.68 x 10-8ρ
8.50 x 10-8ρ

Save Money

Copper tabs will connect your power cells more efficiently and do it for more than half the price compared to some nickel.

as of OCT 2020
USD $3.09/lbs USD $7.16/lbs 57% 

Weld Confidently

With copper, attach a thicker tab for a larger spot size and improved peel strength. Plus, the heat affected zone is small, quick and won’t damage the power cell’s internal components.

Nugget Area 5.06mm2 0.29mm2 17x 
Nugget Diameter 2.54mm 0.61mm 4x
Peel Strength 10kg/22lbs 6kg/13lbs 66% 
Thickness 0.010 – 0.020” 0.005 – 0.010” 2x

Sunstone’s Omega PA250i Copper Battery Tab Welder Provides:



Dissimilar Welding Capabilities Copper to steel, copper to aluminum, nickel to steel—ideal for battery welding!
3 Available Configurations 1) Stylus only
2) Weld head
3) CNC table
250 Ws Max Energy The most powerful Sunstone pulse arc micro welder yet!
Weld materials 0.003-.030” (0.075-0.75mm) in thickness Perfect for attaching copper tabs to power cells
Digital Control Adjust and control all energy attributes with color touch screen
Visual Waveform Graphs View energy waveforms and histograms
PLC-Ready With 5 outputs/2 inputs easily integrates into your production process
CNC Compatibility Attaches to any CNC table, like the Janome Cartesian Robot, for maximum production levels
127 Remote Schedules Saves time with access to saved welds
Import/Export Saved Welds Easily transfer settings to other units
Lock-Out Mode Prevent changes to production settings
Alarms and Warnings Avoid time-consuming errors or potentially hazardous conditions
Built-in Training How-to videos always at your fingertips
WiFi Software Upgrades On-board software is easily maintained


Overview and Applications

The Omega PA250i Copper Tab Battery Welder is capable of welding highly conductive metals such as copper and aluminum. It also comes in a CNC version that is capable of performing all the same tasks with the assistance of a CNC table.

This system brags an all new design and performance. This latest update takes all of the great features from our previous model and adds to it a new motorized weld head adding greater control, precision, and uniformity to every weld. Manufacturers can produce lighter, more compact battery packs without compromising power or capacity.

Features and Benefits of the Sunstone Omega PA250i Copper Battery Tab Welder:

  • Solderless Connections – The metals are fused together at the weld spot for a continuous connection and no voltage drops.
  • Clean Weld Spots – During the welding process, surface contaminants are burned off, allowing for strong, clean welds.
  • Weld Dissimilar Metals – Sunstone Spot Welders can weld any combination of metals, such as Copper to Aluminum.
  • Small Heat Affected Zone – The heat-affected zone (HAZ) is very small and very localized to ensure no degradation to the battery. The 250i provides enough energy to make the weld without affecting the integrity of the cell.

More About the Omega PA250i Copper Tab Battery Welder System

The Omega PA250i is the perfect copper battery tab welder.  The Omega PA250i has a new design to give superior performance. This newest update takes all of the great features from our previous EV copper tab battery welder, and adds to it a new motorized weld head for greater control, precision, and uniformity to every weld. The power supply has also been upgraded to offer superior control and fine-tunabilty to guarantee the perfect weld can be achieved.  Manufacturers can produce lighter, more compact, and more efficient battery packs without compromising power or capacity.

The Omega PA250i in Action

Customer Spotlight on Vantage Power


    • Weight

      37 lbs

    • SKU


  • Micro TIG (Pulse Arc) Welder Specifications
    • Welding Energy Range (Joules)

      0.2-250 Joules

    • Weld Spot Diameter Range

      ≈ 0.1 – 4 mm

    • Display (Touch Screen)

      25 cm

    • Max Weld Speed

      1 weld/0.5 seconds

    • Available Weld Energy Settings


    • High Frequency Agitation Options


    • Save Setting Spaces


    • 5x Microscope Magnification


    • Microscope IR & UV Eye Protection


    • 20+ On-screen Languages


    • Arc Start Technology


    • Tack Mode


    • Basic Screen Metal Presets


    • Adaptive Weld Ignition


    • Dynamic Energy Adjustment


    • Multiple Welding Waveforms


    • Pico Mode