Custom Electrical Busbars

We provide custom electrical busbars designed to meet your exact specifications offering efficient, reliable power distribution for panels, switchgear, and high-performance systems.

Low Quantity Runs
A black and white drawing of a stopwatch on a white background.
Expedite Options Available
A black check mark on a white background.
98.2% First Time Quality

Custom Busbar Manufacturing Process

01

Submit Job Files/ Prints

Submit job files, requirements and prints for quoting and DFM review.

02

Laser Cut Busbar Flat Patterns

Materials recommended: copper and aluminum 

Minimum material thickness: .010"

Maximum material thickness: .500"

Hole size tolerance +- .005"

03

Form Parts

Standard bend tolerances: +-.020"

Specialty bend tolerances: < +- .005"

04

Secondary Processes

Finishes offered: tin plating, silver plating and gold plating


Press fit hardware: threaded inserts and threaded studs

What Are Electrical Busbars?

What Are Electrical Busbars?

An electrical busbar is a heavy-duty conductor, typically aluminum or copper used to carry high currents within electrical equipment. Busbars serve as a central point where multiple incoming and outgoing circuits connect—converging power in one location and distributing it to various feeders.

Material / Plating

We offer a wide range of copper and aluminum alloys and can source specialty materials to meet your project’s requirements.

Plating options include standard or matte tin, as well as silver and gold finishes.


Battery Power Distribution

Busbars are the preferred method for connecting battery packs in electric vehicles and energy storage systems due to their rigidity and slim profile. Unlike traditional applications that use uninsulated copper, EV battery systems often use insulated aluminum busbars to reduce weight without compromising performance.

Types of Busbars

There are several types of busbars we offer, each designed for specific applications. Solid busbars are rigid bars made of copper or aluminum, ideal for high-current systems. Insulated busbars are coated for safety and space efficiency, commonly used in EVs and compact systems. The choice depends on current requirements, space constraints, and environmental conditions.

Common Uses for Electrical Busbars

Engineers use busbars in electrical systems when they offer clear design advantages over traditional wiring or cabling. Common applications include power distribution panels, switchgear, electric vehicles, battery storage systems, data centers, and industrial control systems. Busbars provide better current handling, improved organization, reduced space requirements, and enhanced thermal performance in these environments.

Renewable Energy Systems

In renewable energy systems like solar, wind, and hydro, efficiency is essential. Busbars offer a reliable and efficient way to transfer power within these systems, providing both performance and design flexibility.






How can we help with your project?


Additional Services We Offer

A black and white icon of a laser cutting machine on a white background.

Laser

Metal laser cutting is a precise, high-speed process that uses a focused laser beam to cut through steel, aluminum, and other metals with clean edges and minimal waste. 

A black and white drawing of a square on a white background.

Forming

Press brakes use force to bend sheet metal into precise angles and shapes. It’s ideal for creating brackets, enclosures, and structural components with consistent, accurate bends.

A black and white silhouette of a welding torch on a white background.

Welding

We use welding to join metal parts and bring your projects to life. Whether it’s custom frames, structural components, or detailed assemblies built to last.

A black and white drawing of a screw on a white background.

Hardware Installation

Hardware installation involves adding fasteners, inserts, studs, or other components to metal parts, preparing them for final assembly and use.

A black and white silhouette of a camera on a white background.

Powder Coating

Powder coating gives metal parts a durable, clean, and professional finish. It's applied as a dry powder and cured with heat for a long-lasting, chip-resistant surface in a wide range of colors.

A black and white drawing of a curved line on a white background.

Edge Rounding

Edge rounding smooths sharp edges on metal parts after cutting, improving safety, handling, and paint or powder coating adhesion.

Why Us?

98.2% First Time Quality

2024-2025 ISO RMA Report

Work Orders Completed: 697

RMA Precentage: 1.8%