Busbar Systems

Busbar Systems are essential components in modern power distribution networks. A busbar system provides a reliable, efficient, and safe solution for carrying and distributing high current from power sources to various electrical devices. Compared with traditional cable wiring, busbars offer superior conductivity, reduced energy loss, better heat dissipation, and a more compact structural layout.

Busbars are typically made from Copper (Copper Busbar / Solid Copper Busbar / Flexible Copper Busbar) or Aluminum (Aluminum Busbar / Flexible Aluminum Busbar) depending on current capacity, system design, and budget requirements.

Our factory specializes in the design, manufacturing, machining, plating, insulation coating, and customized assembly of Busbar Systems for industrial, commercial, automotive, rail transit, renewable energy, and data center applications.

1. What Is a Busbar System?

A Busbar System is an integrated conductor network used to collect power from input terminals and efficiently distribute it to output circuits.

It can include:

• Conductive Busbars (Copper / Aluminum)

• Flexible Busbars (Laminated or Braided)

• Insulation Layers (PVC, Heat-Shrink, Epoxy Coating)

• Busbar Support Insulators & Mounting Hardware

• Connectors / Terminals / Fastening Components

The structure is designed to handle high current load while maintaining mechanical stability and electrical safety.

2. Busbar System Structure

3. Types of Busbars We Manufacture

3.1 Solid Busbar

• Made from T2/C1100 Copper or 1060/6061 Aluminum

• Rigid, high current capacity

• Used in power distribution cabinets, switchgear rooms

3.2 Flexible Busbar

• Laminated layers or braided copper/aluminum strips

• Absorbs vibration & thermal expansion

• Ideal for battery energy storage systems (BESS), electric vehicles, transformers

3.3 Flexible Copper Busbar

• Highest conductivity (up to 99.9% IACS)

• Used in high-performance, compact electrical systems

3.4 Flexible Aluminum Busbar

• Cost-effective and lightweight alternative

• Used in large-scale renewable power systems

4. Key Advantages of Busbar Systems

5. Application Fields

Our Busbar Systems are widely used in:

• Power Distribution Cabinets & Switchgear

• Industrial Automation Systems

• UPS & Data Center Backup Systems

• Solar PV Inverters & Energy Storage Batteries

• EV Powertrain & Battery Pack Busbar

• Marine and Railway Electrical Systems

• Wind / Solar Renewable Power Plants

• HVAC and Building Electrical Distribution

6. Custom Manufacturing Capabilities

Materials Available

• Copper: T2, C1100, C1020 (High Conductivity)

• Aluminum: 1060, 3003, 6061 (Lightweight Options)

Processing Techniques

• CNC Cutting / Stamping

• Precision Bending & Forming

• Punching & Slotting

• Welding & Brazing

• Tin / Nickel / Silver Plating

• Epoxy Insulation Coating or Heat-Shrink Insulation

Custom Shape Support

• Flat

• Bent (L, U, S, Z shapes)

• Laminated Flexible Structure

• Braided Soft Connectors

7. Why Choose Us

• Over 15+ years manufacturing experience

• OEM & ODM Design Service

• Strong R&D Engineering Support

• ISO Quality-Controlled Production

• Direct Factory Pricing

• Stable Global Supply Chain Delivery

We supply to:

FAQ — Frequently Asked Questions

Q1: What is the difference between Copper Busbar and Aluminum Busbar?

• Copper Busbar has higher conductivity, better mechanical strength, and lower resistance loss.

• Aluminum Busbar is lightweight and cost-effective but requires a larger cross section to carry the same current.

Rule of Thumb:
1 mm² Copper ≈ 1.6 mm² Aluminum (Current capacity equivalence)

Q2: How to choose the right busbar cross section?

1. Determine rated current

2. Check voltage drop & temperature rise limits

3. Select cross section from current capacity table

4. Apply correction factors for installation environment (heat, airflow, insulation)

We can calculate for you if you provide:

• Current (A)

• Voltage (V)

• Installation environment

• Expected continuous operation hours

Q3: Can you manufacture custom-shaped busbars?

Yes — we support OEM / ODM.

Available processing:

• CNC Cutting

• Laser Profiling

• Bending (L, U, Z, S shapes)

• Punching / Drilling

• Laminated bonding

• Welding & Capping

Simply provide: Drawing / CAD / Sample / Technical Requirements

Q4: Do you supply Insulated Busbars?

Yes — we offer:

• PVC / PE extrusion insulation

• Epoxy resin coating insulation

• Heat-shrink insulation

• Custom color marking for polarity (+/-)

Q5: What is the lead time?

• Standard sizes: 3–7 days

• Customized shapes: 7–20 days

• High-volume OEM: Negotiable based on schedule

Q6: What industries use your busbar systems?

• UPS & Data Centers

• Solar & Energy Storage (ESS)

• Electric Vehicles and Battery Packs

• Power Distribution Cabinets

• Industrial Automation

• Telecom Power Supply

• Rail & Marine