This paper presents an innovative approach that uses a pulse-profile to improve the welding quality of CP1180 steel in resistance spot welding process. Three pulses with two cooling times were used in the developed multi-pulse welding (MPW) schedule. The experimental results show that the first pulse increases the contact area between the sheets to improve the current flow pattern. The second pulse was designed to extend the sheet-to-sheet contact area and corona bond for preventing rapid nugget growth. Using these designs, the nugget size was maximised through the third pulse. The maximum nugget size using the designed MPW schedule was 18.5% greater than that of the single-pulse welding schedule and the weldable current range was extended by 130%.
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