Flexible Busbar

Looking for a high-performance Flexible Busbar or a reliable Custom Busbar Manufacturer? We specialize in producing Flexible Aluminum Busbars, Laminated Busbars, and customized battery connection solutions for electric vehicles (EVs), power systems, and industrial energy distribution.

What is a Flexible Busbar?

A Flexible Busbar is a multi-layer aluminum foil conductor bonded through pressure or welding processes. Compared to traditional rigid busbars, flexible busbars offer lightweight construction, excellent flexibility, and superior vibration resistance.

Flexible Aluminum Busbars are particularly suitable for compact installations and high-current density systems.

Application Scenarios

Our Flexible Aluminum Busbars are widely used in:

• EV Battery Systems (Flexible Aluminum Busbar for EV)

• Inter-cell connections

• Module-to-module connections

• Module-to-pack current transmission

• Energy storage systems (ESS)

• Industrial switchgear and power cabinets

• UPS and inverter systems

• Railway, aerospace, and photovoltaic industries

Custom Flexible Busbar Manufacturer Services

As a professional Custom Flexible Busbar Manufacturer, we support:

• Size Customization: Width, length, and foil thickness ranging from 0.05 mm to 1.0 mm

• Layer Options: Up to 60+ aluminum layers

• End Processing: Hole punching, riveting, ultrasonic welding, press welding

• Insulation Coating: PET, PVC, heat shrink tubing, etc.

Laminated Busbar Capabilities

We offer Laminated Busbars designed to minimize inductance and resistive losses, enhancing system performance. These busbars are ideal for high-power environments due to their:

• Compact structure

• High thermal stability

• Low impedance path

• Modular integration capabilities

Materials and Surface Treatments

• High-purity aluminum foil (1060/1070)

• Optional tin-plating or nickel plating

• Copper-aluminum hybrid busbar customization available

• Flame-retardant and heat-resistant insulation options

Why Choose Us?

• Over 10 years of busbar manufacturing experience

• ISO 9001 and IATF 16949 certified production facilities

• Full in-house testing with complete traceability

• OEM and ODM customization support

• Stable global delivery capability

Whether you're sourcing for standard items or need a fully customized Flexible Aluminum Busbar or EV Battery Busbar, we deliver dependable, high-performance solutions tailored to your project needs.

Frequently Asked Questions

Q1: What's the difference between a flexible busbar and a rigid busbar?
A: Flexible busbars are lightweight, space-saving, and vibration-resistant, making them ideal for mobile and compact environments such as EV battery packs. Rigid busbars, usually made of copper or solid aluminum, are suitable for static installations.

Q2: Why use Flexible Aluminum Busbars in EV battery systems?
A: EV batteries require connectors that withstand vibration and thermal expansion. Flexible busbars improve durability, reduce stress on terminals, and enhance safety.

Q3: Can I customize the Flexible Busbar for my application?
A: Yes. As a Custom Busbar Manufacturer, we provide full support for dimensional, structural, and material customization. Drawings and samples are welcome.