Battery terminal application by Baltec

Battery Terminal

The challenge with creating electrical connections is on one hand to form material tight to achieve gap-free contact between the joined components.

The tight connection should achieve very high continuity and prevent corrosion. On the other hand, applying excessive force should also be prevented, which may deform components.

The radial process is extremely effective in forming material in three different directions, or 3-dimensionally, while keeping the applied force to a minimum. With optimized process parameters and tooling, the deformation of components can be prevented and still meet customers' requirements.

Facts & Figures

Reference No. BCHA1035
Forming Process Radial
Material Copper, brass, aluminum
Geometry Various – relay contacts to heavy gauge, high current cables
Shank type Solid and tubular rivets. Round or rectangular
Rivet head geometry Flat, crown, eyelet flare, flat flare, high crown
Forming Tool Per application
Performance Data Typical forming time: 0.3 – 1.0 sec. Typical machine cycle time : 1.0 – 2.0 sec.
Equipment CLASSIC or ELECTRIC radial forming
Application Area Electrical terminals and connections, bus bar riveting, electrical power rail, battery terminals
Devices Most applications: 2-6 kN. Occasionally up to about 20 kN
Process Control HPP-25 or HPPi
User Benefits: Process Excellent gap filling with minimal necessary force
User Benefits: Economic Flexibility regarding setup. Process stability & assurance of quality product being produced

This project was realized by BalTec AG

For further questions or detailed information contact:

BalTec AG
Obermattstrasse 65
8330 Pfäffikon

Phone:   +41 (0)44 953 13 33
E-mail:   baltec(at)