Custom Busbars & CNC Bending
Precision manufactured Copper and Aluminum Busbars for EV, ESS, and Heavy Industry. We offer full-service fabrication: CNC bending, punching, plating, and electrical insulation coating.
Beyond Flat Strips: The Need for 3D Geometry
Modern battery packs are compact puzzles. To connect modules across different planes while managing thermal expansion and vibration, you need more than a flat strip. You need precision-engineered 3D Busbars.
CNC Bending Accuracy
We utilize 5-axis CNC bending machines to create complex shapes with ±0.1mm/±0.5° tolerance. This ensures your busbars fit perfectly around cooling plates and BMS components without mechanical stress.
Thermal Management
Thick copper busbars (2mm - 10mm+) act as heat sinks. By customizing the width and path, we help you direct heat away from sensitive battery cells, improving pack longevity.
High Voltage Safety
For 400V/800V EV architectures, insulation is critical. We offer in-house epoxy powder coating and dipping to provide dielectric protection up to 5000V DC.
Material Selection Strategy
Choosing between Copper and Aluminum is a trade-off between weight and conductivity.
| Material | Conductivity (IACS) | Density (g/cm³) | Best Application |
|---|---|---|---|
| Copper T2 (C1100) | ≥ 99.9% | 8.96 | Compact, High-Power EV & Industrial |
| Aluminum (1060) | ~ 62.0% | 2.70 | Weight-sensitive EV & Aerospace |
Surface Plating Options
Nickel Plating (Standard)
Prevents oxidation, improves corrosion resistance, and enables spot welding to sensors.
Tin Plating (Sn)
Reduces contact resistance, ideal for bolted connections and preventing galvanic corrosion with aluminum.
Advanced Insulation & Flexible Solutions
Safety is non-negotiable in high-voltage systems. We provide industry-leading insulation technologies.
Laminated Flexible Busbars
Vibration is the enemy of connections. Rigid bars can crack under stress. Our flexible busbars are made of stacked thin copper foils (0.1mm layers), allowing them to flex and absorb vibration.
- Expansion Joints: Absorbs thermal expansion of battery cells.
- Installation: Forgives misalignment during assembly.
- Insulation: Dipped PVC or Heat Shrink tubing.
Epoxy Powder Coating
For rigid busbars, we use electrostatic spray powder coating (orange/red/black). This creates a hard, durable insulation layer that bonds directly to the metal.
- Dielectric Strength: >20kV/mm.
- Heat Resistance: Class F (155°C) or Class H (180°C).
- Precision: Masking of contact areas ensures perfect conductivity where needed.
Powering Heavy Industry
Our custom busbars are deployed in critical infrastructure worldwide.
Commercial EV / E-Bus
Data Centers & PDU
Grid Energy Storage
Solar Inverters
Generally, the minimum inside bend radius is equal to the thickness of the material (1xT) for soft copper. For harder tempers or aluminum, we recommend 1.5xT to 2xT to prevent cracking on the outer edge. Our engineers review every design for feasibility.
Heat Shrink is cheaper and good for simple straight bars. Epoxy Powder Coating is superior for complex 3D shapes because it adheres to the metal surface seamlessly without air gaps, offering better thermal dissipation and higher breakdown voltage safety.
Yes. We manufacture diffusion-bonded flexible connectors (soft copper foils fused at the ends). These are essential for absorbing vibration in EV packs and compensating for thermal expansion between rigid modules.
For 3D bent busbars, we require 3D STEP (.stp) or IGES files. For flat punched parts, 2D DXF/DWG is sufficient. Please also include a PDF drawing indicating critical tolerances and plating requirements.
We partner with certified automotive-grade plating facilities to ensure compliance with salt-spray tests (typically 48h to 96h requirements). We perform the final QC inspection before shipping.
Engineer-to-Engineer Support
Our Latest News
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