That is really interesting. 

http://www.hobbyspotwelders.com/HS300A2.php

The welder controller, which apparently is a DC spot welder, is a curious object.  In a conventional spot welder, you have a big transformer, and the spot weld is controlled by time.  The longer the time, the hotter the weld, and the more metal it will go through.  In this one, apparently, you control the voltage on a capacitor instead.  Nice 24V isolated input from a cheap wall wart.

This would not be so hard to build.  It is basically a power supply with a controlled charging time, and a large, low ESR, high current capability capacitor with a high current switched output.  The $325 clams they charge for it sounds pretty steep compared to what it is.  PIC? 

It is AMAZING what you can do with a spot welder, a notcher, and a press brake.  Boxes, standoffs, mounting brackets, all this stuff becomes a piece of cake.  

-- Lawrence Lile, P.E.
Electrical and Electronic Solutions
Project Solutions Companies
www.projsolco.com
573-443-7100 ext 221

> -----Original Message-----
> From: Eisermann, Phil [Ridg/CO] [mailto:peiserma@ridgid.com]
> Sent: Tuesday, October 19, 2004 2:22 PM
> To: 'Microcontroller discussion list - Public.'
> Subject: RE: [EE]: Battery Spot welding...
> 
> piclist-bounces@mit.edu wrote:
> > Guys,
> >
> > Got an application where we're looking into making up a bunch of
> > battery packs.  Does anyone have a good source or experience with any
> > spot welders specifically for welding battery tabs?  I can find them
> > for like $12k-14k, but I can't quite justify that.  Need something
> > ~$5k-$8k range.
> 
> a recomendation from a co-worker is http://www.hobbyspotwelders.com/
> 
> It has an attachment specifically for battery tab welding. The
> power supply plus attachment is like $400
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