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Solid Copper Busbar
As a professional Copper Busbar manufacturer for battery packs, we provide precision-engineered Copper Busbars designed for EV battery modules, lithium-ion battery packs, and energy storage systems. These high-conductivity Copper Busbars ensure minimal voltage drop and optimal thermal performance in demanding battery applications.
We support both flexible and solid copper busbar designs, including laminated, CNC machined, and plated versions such as tin-plated Copper Busbars. Whether you're developing a new BMS (Battery Management System) or need reliable battery interconnects, we are your trusted custom battery copper busbar supplier.
Made from T2 pure copper (≥99.9%), ensuring ultra-low resistance and high current capacity, critical for electric vehicle and high-load battery systems.
Support for custom hole patterns, lengths, bends, and plating to seamlessly match your battery architecture and save assembly time.
Available in bare copper, tin-plated, nickel-plated, or silver-plated, providing enhanced corrosion resistance and optimized weldability or bolted connection.
Copper busbars can withstand high current flow and thermal cycling without warping or degradation—ideal for high-demand applications.
From solid copper bars to laminated and flexible copper connectors, we support diverse project needs for both fixed and vibration-sensitive environments.
We are an OEM battery copper busbar supplier, offering in-house CNC machining, prototyping, quality inspection, packaging, and export logistics.
| Parameter | Specification |
|---|---|
| Material | T2 Pure Copper (≥99.9%) |
| Type | Solid Copper / Laminated Copper / Flexible Copper |
| Cross-section Size | 10 mm² – 3000 mm² (customizable) |
| Thickness | 1 mm – 10 mm |
| Width | 5 mm – 50 mm |
| Length | Up to 1000 mm |
| Surface Finish | Bare, Tin-plated, Nickel-plated, Silver-plated |
| Insulation Option | Heat shrink tubing, Epoxy coating, PET layer (optional) |
| Voltage Rating | Up to 1000V DC |
| Current Rating | 50A – 1000A (depending on size/design) |
| Operating Temperature | -40°C to +125°C |
| Tensile Strength | ≥200 MPa |
| Hole Customization | CNC drilling, slotting, multi-layer stacking |
| Application | EV battery modules, BMS, ESS, solar storage battery packs |
| Certifications | ISO 9001, RoHS, UL (on request) |
Our copper busbars for battery packs are engineered to meet the electrical, mechanical, and thermal demands of various high-performance energy systems. They are widely used in:
Battery interconnection
Battery Management System (BMS)
Power distribution and current balancing
Cell-to-cell and module-to-module connection
DC energy transfer between solar cells and battery units
Connection of lithium batteries in off-grid and hybrid solar systems
Copper busbar modules used for fast and stable power transmission
High current routing in industrial backup power systems
Copper connectors used in battery backup banks
Redundant power architecture requiring low-resistance busbar networks
Custom-designed busbars for modular battery testing systems
Copper interconnects in rack-mount energy storage units
FAQ – Copper Busbar for Battery Pack
Q1: Can your copper busbars be customized for EV battery modules?
A1: Yes. We provide full customization including size, shape, hole positions, plating, and insulation—ideal for EV battery packs and BMS systems.
Q2: What type of copper do you use?
A2: We use T2 pure copper with ≥99.9% conductivity, ensuring minimal resistance and high performance in power applications.
Q3: Do you offer both solid and flexible types?
A3: Yes, we supply solid copper busbars, laminated copper busbars, and flexible copper busbars depending on the thermal and structural needs of the battery design.
Q4: What are the benefits of tin- or nickel-plated busbars?
A4: Tin plating enhances oxidation resistance and weldability; nickel plating provides better protection in high-temperature or corrosive environments.
Q5: Can I get a prototype before mass production?
A5: Yes. We support low MOQ and fast sample lead time for prototypes, making us a preferred OEM copper busbar fabricator for battery packs.
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