Customized Copper Busbar for EV

Our Customized Copper Busbar for Electric Vehicles is engineered to deliver superior electrical conductivity, thermal performance, and mechanical durability. Designed specifically for modern EV battery systems, power distribution units (PDUs), and battery management systems (BMS), these busbars can be fully tailored in shape, size, plating, insulation, and punching pattern to meet the unique needs of automotive OEMs and energy storage integrators.

Product Features

• Excellent Conductivity: Made from high-purity T2 copper, offering low resistance and minimal power loss.

• Custom Design: CNC-machined and punched according to customer-supplied drawings or technical specifications.

• Surface Treatment Options: Available with tin, nickel, or silver plating for enhanced corrosion resistance and current carrying performance.

• Insulation Protection: Optional heat-shrink tubing or epoxy powder coating to provide electrical insulation and protection from short circuits.

• High Mechanical Strength: Designed to withstand vibration, bending, and thermal expansion common in automotive environments.

• Flexible Assembly: Available in both rigid and laminated flexible forms to accommodate complex system layouts.

• RoHS & REACH Compliant: Manufactured under strict quality standards and compliant with international regulations.

Product Specifications

Application Fields

• Electric Vehicle Battery Packs (EV/HEV/PHEV)

• Battery Management Systems (BMS)

• Power Distribution Units (PDU)

• Charging Infrastructure / Fast Chargers

• Energy Storage Systems (ESS)

• Industrial Inverters and Power Electronics

• Hybrid Vehicle Converters and Inverters

FAQ

Q1: What’s the advantage of using copper busbars in EVs?
A1: Copper offers superior conductivity, reducing energy loss, and supports high current loads in compact areas — critical for EV battery and motor systems.

Q2: Can I customize the shape and hole layout of the busbar?
A2: Yes. We support full customization based on CAD drawings or technical specifications provided by the client.

Q3: What insulation options are available?
A3: We offer PVC or PE heat shrink insulation, as well as epoxy coating for enhanced dielectric strength.

Q4: Are your products certified for automotive use?
A4: Yes, our copper busbars comply with ISO 9001 and IATF 16949 standards, ensuring consistent quality for automotive applications.

Q5: Do you provide prototype and low-volume services?
A5: Yes, we support both small-batch prototyping and mass production with flexible lead times.