Terminal welding

our know-how for stable stranded terminal connections

Terminal welding – high-quality connections with the lowest possible transition resistance

Terminal welding by means of resistance technology enables the connection of cable strands or pigtails to various components such as: contacts, plugs, welding rings, switches and others. With the resistance welding it is possible to process the strands with a cross section of 0.1 mm² (micro area) to 300 mm². The various mixed compounds and also special alloys can be connected here.

Resistance welding of stranded wire on terminals offers several advantages. On the one hand, the connections impress with their high mechanical strength (pull and peel force) and contact resistances that tend towards zero. On the other hand, they show no aging and no susceptibility to dirt, drawing oils or oxidation. This means that there are no abnormalities in the

  • Mechanical stress
  • Electrical stress
  • Dynamic stress
  • Environmental test, such as temperature (change), dry and wet heat or salt spray

Aging, derating or vibration tests cannot harm our connections. This is made possible by a cohesive and “real” welded connection in the hot phase.

Another advantage of resistance welding is the possibility of being able to weld very short strands (20 mm or less) on both sides to a terminal or other connection surfaces. The terminals can also be tinned. In addition, mixed connections (metal-metal) can be realized.

With terminal welding, important parameters such as installation space, contact part geometries, alloys and coatings (electroplating) must already be coordinated during planning and development. We therefore recommend that you make use of STRUNK Consulting in order to guarantee process-reliable terminal connections.


Three different methods of terminal welding

1. By adapting the width of the terminal to the strand cross-section, it is possible to weld on a cable directly without prior compacting.

2. The direct welding of uncompacted lines can also be realized with a special tool. You will receive further information on this as part of the consulting.

3. With this variant, the strand is compacted in a preliminary process and then welded onto the terminal. This is often done in automated systems (e.g. transfer systems) when the installation space of the contact (e.g. in the housing) does not allow direct welding. All versions can also be shown under hard solder.

With terminal welding, strands with a cross-section of 0.1 mm² (micro range) to 300 mm² can be processed. The terminal connections can also vary in cross-section. To do this, we must first check the initial samples or customer samples in our in-house laboratory for technical feasibility (prototype development). In doing so, we are already gaining initial knowledge for industrialization.

As soon as the application is classified as technically feasible and reliable, we will work out a proposal for industrialization based on your quantities and your production process. You have the choice between a manual workstation, a semi-automatic version and a fully automatic version with upstream and downstream processes. Depending on this, we realize for you:

  • Welding modules with customer-specific tools for manual activities,
  • Machines in cell construction with automated processes and manual loading or
  • Interlinked production lines as a transfer rotary indexing table or tool carrier system.

Automated welding and feeding of terminals to wire processing centers using special modules is also possible

STRUNK – your partner for terminal welding in a wide variety of industries

In order to enable you to create reliable connections of strands and components to end connectors, we adapt the necessary tools exactly to your applications or redesign them if necessary. In this way, we ensure the required positioning of the individual elements and thus also the constant energy density per square millimeter.

Depending on the geometric shape of the components and the contacting surfaces, it is either possible to weld on the strands in a precompacted manner or to create the connection in a direct work step. In the second variant, compacting and welding take place simultaneously in one working stroke. For this purpose, the geometric shape of the connection surface of the component must be matched exactly to the strand cross-section.

With our systems for terminal welding, we guarantee maximum efficiency and quality as well as good handling during the production process. Whether you are looking for a manual workstation for manual production, a mobile device for sequential production on the cable board or modules for integration into existing machines or lines – you have come to the right place. In addition, STRUNK offers you semi-automatic cells and fully automatic production lines for terminal welding, with which an almost infinite range of applications in areas such as automotive, medical technology, solar, photovoltaics, electrical appliances and defense can be covered.

By combining our intelligent power sources with customer-specific tools, it is also possible to weld mixed connections and special alloys. Our team will be happy to check the technical feasibility of your application in the laboratory and create initial samples for you. Get in touch with us today.


(Individual customer solution as an example)

S-MMD1 with double welding tool for high temperature cables on contacts

The S-MMD1 system is for welding pre-crimped contacts with a double welding tool for position and orientation …

S-MMD3 with special tool for slip ring welding as a change system

MSK micro welding head for connecting braid to switch contacts under hard solder

MSK micro welding system with customer-specific change tool and manual solder feed & automatic solder separation. Machine structure …

Special welding cell for connecting multiple strands to terminals

Semi-automatic system with WT system for lead frames, DMC labeling and camera system …

Rotary table for fully automatic processing of junction boxes in the solar industry

8 stations turntable for the fully automatic welding of diodes and cables on overmolded leadframes

Welding module for integration on KOMAX / SCHLEUNIGER cable processing centers with automatic contact feed

Airbag contacts with contact strip conveyor in side connection or with module feed-through …