Industry
EV Battery and Busbar Parts
Copper and aluminium busbars, cell connectors, module brackets and pack hardware where contact resistance and plating thickness matter more than appearance.
Direct answer: we make busbars, cell connectors, module brackets, pack hardware and charging parts in copper (C11000, C18150) and aluminium (1060, 6061). Typical tolerance is ±0.05 mm on contact faces, plating is silver, nickel or tin from 1 to 5 µm, and every batch is checked for plating thickness and dimensional conformity. Parts are produced from prototype to tens of thousands per year.
Parts we make
- Busbars – flat, stepped, laminated and insulated, with punched or drilled holes and plated or masked joint areas
- Cell connectors and module links with defined contact faces and bend radii
- Module and pack brackets, spacers and mounting plates in aluminium or plated steel
- Terminal lugs, contact plates and shims in copper and brass
- Charging hardware parts such as pins, contact sleeves and mounting plates
- Heat spreaders and thermal interface plates in aluminium
Process route and what it controls
| Part feature | Process | What is controlled |
|---|---|---|
| Flat profile and hole pattern | Fibre laser cutting or stamping | ±0.10 mm on cut edges, hole position within ±0.05 mm where specified |
| Bends and offsets | CNC bending | Bend position ±0.10 mm, angle ±0.5°, no cracking on the outside radius |
| Contact faces | Machining or fine blanking | Flatness and ±0.05 mm on joint faces, burr removed to avoid contact resistance |
| Plating | Silver, nickel or tin plating | 1 – 5 µm silver, nickel barrier layer 1 – 2 µm, adhesion tested, masked areas kept conductive |
| Insulation | Heat shrink, powder coating or insulating film | Wall thickness, dielectric strength, no gaps at the bend |
| Marking | Laser marking or stamping | Part number and polarity marking that survives plating and cleaning |
Materials
| Material | Typical grade | Why it is used |
|---|---|---|
| Copper | C11000 (ETP), C18150 (chromium zirconium) | Highest conductivity for busbars and connectors; C18150 keeps strength after bending |
| Aluminium | 1060, 6061 | Light weight busbars and brackets where weight matters more than conductivity |
| Nickel-plated steel | SPCC or DC01 with nickel plating | Lower cost brackets and shield parts that still need corrosion resistance |
| Brass | C2680, C2801 | Terminals and contacts where machinability and conductivity are both needed |
Design rules that avoid surprises
- Define the contact area and the current path on the drawing. Plating is only applied where conductivity is needed, and masking keeps cost down.
- State the allowed resistance increase after plating rather than only the plating thickness – thickness alone does not guarantee a low-resistance joint.
- Keep bend radii at 1 x thickness minimum for copper and annealed grades; hard grades crack at tight radii.
- Allow for plating thickness on threaded holes and press-fit features, or specify masking.
- Call out burr direction and edge quality on contact faces, because a burr raises contact resistance and can puncture insulation film.
- Give the flatness requirement on joint faces explicitly; it is not implied by a general tolerance.
Inspection we run on this part family
- Plating thickness on the contact area and on the masked area, measured per batch
- Adhesion test after plating, especially on bent surfaces
- Dimensional report on hole pattern, bend position and joint face flatness
- Visual check for burrs, scratches and plating stains on contact surfaces
- Resistance or continuity check on request, with the test method agreed before production
Frequently asked questions
What copper grades do you use for busbars?
C11000 (ETP copper) is the default for conductivity, and C18150 (chromium zirconium copper) is used where the part must keep strength after bending or where higher temperature strength is needed. The grade is stated on the material certificate for each order.
Which plating is best for a busbar joint?
Silver plating gives the lowest contact resistance and is the usual choice for joints; nickel is used as a barrier layer under silver or on its own for wear resistance; tin is used where solderability matters. Thickness is quoted from 1 to 5 µm depending on the joint requirement.
Can you supply insulated busbars?
Yes – heat shrink tubing, powder coating or insulating film, with the insulation wall thickness and dielectric requirement agreed at quotation. The joint areas are left uncoated or masked.
Do you test resistance?
Resistance or continuity testing is available, and the test method, sample size and acceptance limit are agreed before production so the result is comparable with your incoming inspection.
Send the busbar drawing and the joint requirement
Include the current path, plating requirement, resistance limit and annual volume. The quotation states the process route and the inspection plan.