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Parallel Gap Welding

Gap Welding is the process of bonding two parts together by placing both electrodes against the same surface on just one part. Weld current flows from one electrode through the top part and partially into the bottom part before returning to the power supply via the second electrode (see figure).

Gap Welding may be the only viable bonding method when electrode access is limited to one part or the part materials preclude the use of pulsed YAG laser welding.

Parallel Gap Welding Applications


Parallel Gap Welding Benefits:

  • Products can be welded that are only approachable from one side

  • Products that are insulated on one side can be welded (PCB repair)

  • Weld current does not pass through the complete body of the lower part

  • Dual nuggets in one weld operation

Typical Parallel Gap Welding applications can be battery packs, medical or automotive sensor wire to PCB, solar cells, hybrid or microwave circuitry, thin or thick film substrate, potentiometers and other miniature components, semi-rigid substrates and fine line printed circuit trace repair.


Our proven technologies enable the Automotive, Electronics & Solar Cells, IT & Multimedia, Medical, Aerospace and Defence industries to supply a variety of Gap Welding applications.