0.025mm NP1 Nickel Wire – Solving Breakage and Consistency Issues in Battery Tab Production

In the lithium‑ion battery industry, ultra thin 0.025mm nickel wire is widely used for tab connections, where it must carry high current while withstanding repeated bending and heat. However, for years, manufacturers struggled to source 0.025mm nickel wire that combined high purity, consistent diameter, and low breakage rates. Industrial‑grade nickel (around 99.5% purity) caused frequent fractures during drawing, and even when drawn, the wire’s surface defects led to premature failure in battery cells.

We addressed this challenge by developing a proprietary drawing process using 99.9% NP1 pure nickel feedstock. Our wire achieves a diameter tolerance of ±0.001mm and a surface finish smooth enough to prevent micro‑cracks. By optimising die sequences and in‑line annealing, we reduced internal stress and improved elongation, resulting in a breakage rate below 1% during high‑speed automated tab welding.

Today, our 0.025mm wire supplies major battery assembly lines, delivering over 500kg per month. Customers report higher yield rates and fewer production stoppages. The stable quality also allows them to reduce raw material waste and better plan inventory.

For battery manufacturers seeking a reliable ultra thin wire partner, our product offers both technical excellence and supply security. We welcome inquiries for samples – contact us to learn how we can support your production.