Spot-welding power-bank cells with the AWithZ portable welder. Spot-welding power-bank cells with the AWithZ portable welder. After long use a power bank's capacity drops. A shame to throw it away; swap in a few high-capacity cells and it works again

Old power bank re-celled with 5 Panasonic 2700mAh+ cells: AWithZ portable welder on gear 7–8 welding 0.12×6 nickel strip, manual mode with a few extra pulses, welds look great and won't come off, case glued with AB epoxy

After long use the power bank had basically no capacity left, but the case and circuit board are well made and a shame to throw away (it even has a flashlight). The creator found 5 original Panasonic cells, each over 2700mAh, and replaced every cell inside; swapping cells has to be done with a spot welder, here the AWithZ portable welder — very light but works well. Nickel strip 0.12×6mm; set to gear 7 or 8 (out of a dozen or so), no need for maximum; the welds look great and hold so firmly they can't be pulled off — pulling with pliers tears the nickel strip itself. The machine has auto and manual modes: in auto it fires as soon as good contact is made; the creator prefers manual and adds a few extra pulses. Put it back and hold it in place, the flashlight turns on normally, glue the case with AB epoxy. Better than the original when new: original 2000mAh, now 2700–2800mAh per cell.

Outcome

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1. 
   1. Old power bank and Panasonic cells

   The power bank's capacity had faded to basically nothing, but the case and board are well made and a shame to toss, plus it has a flashlight; found 5 original Panasonic cells, each over 2700mAh, and replaced them all; a spot welder is a must for swapping cells.

   00:00 – 00:34
2. 
   2. Portable welder on 0.12×6 nickel strip: neat and solid

   Using the AWithZ portable spot welder — very light but works well; nickel strip 0.12×6; welds look great and hold so firmly they can't be pulled off.

   00:34 – 01:12
3. 
   3. Gear 7–8 (out of a dozen or so), no need for max

   No need to turn it up to max; set to gear 7 or 8; there are a dozen or so gears in total; the welds look great and won't come off — pulling with pliers tears the nickel strip.

   01:12 – 01:57
4. 
   4. Auto vs manual: prefers manual with a few extra pulses

   The machine has auto and manual modes; in auto it fires automatically once contact is good; the creator doesn't like auto and always uses manual with a few extra pulses; welds look great.

   01:57 – 02:30
5. 
   5. Reassemble, test the flashlight, glue with AB epoxy; capacity comparison

   Once assembled hold it in place and turn on the flashlight; glue the case with AB epoxy and done; better than the original when new: original 2000mAh, now 2700–2800mAh per cell.

   02:30 – 03:15

Bill of materials

Creator’s tips

• Gear 7–8 is enough for 0.12×6 nickel strip; no need for max 01:12
• Manual mode is controllable; a few extra pulses make it more secure 02:16
• Pick replacement cells with more capacity than the originals — it ends up better than new 03:03

Li-ion safety

Quotes