@ZachTetra I have the cells already.
Iām in GA, I could weld Pgroups for you, and can ship realtivly cheap. Ping me if youāre interested.
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I know this is kinda a late reply but I designed these and they work pretty well.
What size nickle strip would you use for 21700 cells? 6mm? 8mm? 10mm?
.15 thickness
depends on the cell and the configuration, 10mm is okay for 30A
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depends also on the cell.
Higher power cell may require increased nickel thickness
Molicel p42a. So 10mm .20?
If you can, that would be better
oh wait. youāre going to try and cram welded packs into the NESE, right? as long you donāt pass current along the length of the nickel, you should be fine with whatever.
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how do you guys prepare/clean your nickel and cell surfaces, as well as electrodes, for welding?
Only electrodes need to be cleaned, its obvoious they will get that darker colour to them, just use some fine sandpaper
If I see or feel anything like residue I hit it with some acetone, fingerprints donāt seem to cause any issues. If there is nickel remaining I hit it with a Dremel and stone wheel attachment, ideally a flat finish but the rough texture hasnāt been an issue with the kWeld. If the electrodes are nasty Iāve been shining them with fine sandpaper, Iāll probably get steel wool though
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Iāve been occasionally getting a failed weld with the kweld and it shoots a big spark in the process. Wondering if I ground too far into the cathode/anode or if the surfaces are dirty or what
Did you go off the edge of the positive terminals?
heh, well, I canāt see cause the nickel is wider than the surface 
I do my best, you think Iām goin over the edge? that was my guess
Welding over air 100% causes sparks, take a pick of the cell in question?
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ahh Iāll take photos next time, the packs have all been jumbled up since it was happening last night
Exactly! So .15 should be fine if itās backed with the nese tabs? Im having an issue where 1 of my cells isnāt making contact in the Pgroup. I figured if I welded the Pgroups, it would still allow it to be airline compliant. While still being able to remove the Pgroups without wiring.
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mmaybeā¦
If the NESE pack is not making proper contact, I would address that first. Otherwise, you might end up running the full current along the length of the pack, if, say, only the end of the NESE tab is making contact with the P-group.
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I glued the cells together outside of the nese tabs.
Once they are popped into the cell pocket thatās when im getting the issue. Im not using 3d printed nese housing. That is the reason I want to weld all cells in the Pgroup. That way no matter where the pgroup is touching the nese tab i will have all 4 cells in the Pgroups making contactā¦ make sense?
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