Custom Busbar

What Is a Custom Busbar?

A custom busbar is a specially designed electrical conductor used to distribute power efficiently within electrical systems, switchgear, battery packs, and industrial equipment. Unlike standard busbars, a custom Copper Busbar is tailored to meet specific dimensional, electrical, and mechanical requirements, providing optimized performance for unique applications.

Our solutions include Custom Copper Busbar designs for high-current applications, busbar custom layouts for compact installations, and custom Copper Busbar Supplier services for OEMs and industrial clients worldwide.

Manufacturing Process & Principle

1. Material Selection – High-conductivity copper (ETP Copper ≥ 99.9%) or aluminum is selected based on current rating and application.

2. Precision Cutting & Shaping – CNC stamping, laser cutting, or water-jet cutting ensures accurate dimensions and hole patterns.

3. Surface Treatment – Tin, nickel, or silver plating improves conductivity and prevents oxidation.

4. Insulation & Coating (Optional) – Epoxy resin, silicone rubber, or heat-shrink tubing can be applied to create insulated custom busbar solutions.

5. Quality Inspection – Each custom Copper Busbar undergoes testing for electrical conductivity, thermal performance, and mechanical strength.

The principle behind a busbar custom design is to reduce electrical losses, optimize current distribution, and ensure reliable power delivery under high loads.

Key Features & Advantages

• Tailored Design – Dimensions, hole patterns, thickness, and length can be customized.

• High Conductivity – Using premium copper for low-resistance, high-current applications.

• Durable & Corrosion-Resistant – Plating and optional insulation increase service life.

• Compact Installation – Custom shapes optimize space in switchgear, battery packs, and industrial panels.

• Flexible Solutions – Available as rigid or flexible custom copper busbar to meet dynamic or vibration-prone environments.

• Low Maintenance – Designed for long-term reliability and minimal upkeep.

Material Options

Technical Specifications

Application Scenarios

• Low- and medium-voltage switchgear and distribution panels

• Battery packs and energy storage systems

• Automotive and EV powertrain applications

• Industrial machinery and UPS systems

• Renewable energy inverters and solar/wind power distribution

Installation & Maintenance Tips

• Ensure correct torque on all connection points.

• Avoid sharp bending of flexible custom copper busbar designs.

• Keep surfaces clean to maintain conductivity and insulation integrity.

• Perform periodic inspection for oxidation or loose connections.

Why Choose Us

• Professional Custom Busbar Manufacturer – Full in-house production control for quality assurance.

• Custom Copper Busbar Supplier – Tailored solutions for OEMs and industrial clients.

• Flexible Design Capabilities – Supports busbar custom configurations with precise hole patterns, thickness, and insulation.

• Global Experience – Export-ready solutions with ISO/IEC-compliant quality standards.

FAQ

Q1: Can I order fully custom busbars for my battery pack or switchgear?
A1: Yes, we provide fully custom copper busbar designs according to your specifications.

Q2: Do you offer flexible busbars?
A2: Yes, flexible options are available to reduce vibration and accommodate tight layouts.

Q3: What plating options are available?
A3: Tin, nickel, and silver plating are available to prevent corrosion and improve conductivity.

Q4: Can you handle high-current applications?
A4: Absolutely, our custom copper busbar designs can carry up to 6000A continuous with tested short-circuit withstand.