How to Make a Copper Busbar

A copper busbar is a key current-carrying component widely used in electrical power distribution systems. Compared with standard cables, a copper busbar provides lower electrical resistance, better heat dissipation, and higher reliability in systems that require the transmission of large currents. Understanding how to make a copper busbar helps users, installers, and industrial buyers choose the right specifications, materials, and manufacturing processes for their applications.

This guide explains what a busbar is, what a busbar is used for, and the complete manufacturing process, along with common materials, types, surface treatments, and application scenarios.

What Is a Busbar?

A busbar (also called an electrical bus bar) is a metal conductor designed to collect, transfer, and distribute electricity within electrical power systems. It is typically made from copper or aluminum, and appears as a flat, wide metal bar rather than a cable. This flat shape reduces resistance and improves heat dissipation.

What Is a Busbar Used For?

A busbar is used to:

• Conduct high electrical current

• Distribute power efficiently between components

• Reduce energy losses and thermal buildup

• Serve as a stable and low-resistance conduction path

Busbars are essential in:

• Switchboards and switchgear

• Industrial power systems

• Electric vehicles and battery packs

• Solar and energy storage systems

• UPS and data center power distribution units

What Is the Function of a Busbar?

The main function of a busbar is to safely and efficiently carry large electrical currents. Due to the optimized flat geometry, busbars maintain lower resistance and improved cooling performance, making electrical systems more durable and reliable.

Copper Busbar vs. Aluminum Busbar vs. Flexible Busbar

How to Make a Copper Busbar: Step-by-Step Process

1. Material Selection

The process begins with selecting high-conductivity materials:

• Electrolytic Tough Pitch Copper (ETP, 99.9% purity)

• Optional: Oxygen-Free Copper (OFC) for high-precision applications

The correct thickness and width are chosen based on current rating.

2. Busbar Cutting

Copper sheets or coils are:

• Cut into rectangular strips

• Length, width, and thickness determined by the electrical current requirement

Modern factories use:

• CNC cutting

• Shearing machines

• Laser cutting (for tight tolerances)

3. Hole Punching

Busbars often require connection holes for:

• Terminals

• Cable lugs

• Equipment mounting bolts

This step may include:

• Punching

• Drilling

• Slot milling

4. Edge Deburring and Smoothing

To prevent arc discharge and ensure safety:

• Edges are rounded

• Burrs and sharp surfaces are removed

This step improves both safety and appearance.

5. Bending and Forming (If Required)

For system-specific layouts, the copper busbar may be:

• Bent into U, L, Z shapes

• Twisted or formed to match cabinet spacing

CNC bending ensures dimensional precision.

6. Surface Treatment

Surface plating protects the busbar from oxidation and ensures stable conductivity.

Technical Selection Guide (Ampacity & Dimensions)

Note: Custom sizes available depending on heat rise limits and installation spacing.

Common Applications

• Power distribution cabinets

• Transformer substations

• Generator output systems

• Solar energy storage + inverter systems

• EV battery pack busbar systems

• UPS and data center energy distribution modules

A copper busbar is an essential conductor in modern electrical infrastructure. Its flat profile and high conductivity ensure energy efficiency, stability, and safety. By selecting the right material, dimension, and surface treatment, and by using proper manufacturing processes, copper busbars can deliver long-lasting performance in a wide range of power systems.