Custom Busbars - Flat, Bent, Laminated, Insulated & Machined Designs

Common Sizes (Range Overview)

Materials

• High Conductivity Brass: CW614N / CW617N / CuZn37
• Silver-bearing Brass or CuZn40: For enhanced thermal conductivity
• RoHS-Compliant Lead-Free Brass: CW510L
• Optional: Bimetallic Copper-Brass combinations for hybrid systems

Thread / Mounting Types

• Plain or Threaded Holes (M4-M12)
• Stud Mounting with Hex Nuts
• Slotted Holes for Adjustable Fit
• Mounting Tabs for Chassis or DIN Rails
• Press-Fit or Weldable Ends (on request)

Protection Rating

• IP20 to IP65 depending on enclosure
• Withstands up to 1000V DC (with insulation)
• Vibration-proof with reinforced fixing points
• Custom dielectric coatings for enhanced safety

Surface Finish Options

• Tin Plated (Standard - For anti-oxidation and low resistance)
• Nickel Plated (Industrial-grade corrosion resistance)
• Silver Plated (Premium option - Ultra low resistance)
• Epoxy Coated (Optional for insulated multi-phase busbars)
• Natural Brass (For internal protected units)

Features

• CNC Precision Cut - Slots, bends, cutouts as per drawing
• High Current Capacity - Low heat rise
• Multiphase & Multilayer Options
• Integrated Labels, Color Coding & Markings
• Custom Shapes: U, L, Z, Double Bend, Stepped, Twisted
• Available with heat-shrink or epoxy insulation

Application Areas in EV Sector

• EV Battery Modules - Intra-pack & inter-pack connections
• DC-DC Converters - Compact current routing
• Power Distribution Units (PDUs) - Main busbar carriers
• Onboard Chargers - DC output busbars
• EV Motor Drive Units - High-efficiency multi-terminal bars
• Fast Charging Stations - High current DC linking bars