Customized Special Shape Copper Busbars from China Suppliers and Factory for High-Current Electrical Connections
Technical Specifications
| Item | Value / Description |
|---|---|
| Material | T2 Copper (Cu≥99.99%), Oxygen-free copper optional |
| Cross-Section Size | Custom per drawing (Width ≤300mm, Thickness ≤50mm) |
| Length | 100–6000mm (cut-to-length or any length customizable) |
| Conductivity | ≥58 MS/m (at 20℃) |
| Hardness | Soft (O): HV 45–65; Hard (Y): HV 80–110 |
| Surface Treatment | Bare Copper, Tin-Plated, Nickel-Plated, Dip-Coated/Powder-Coated |
| Insulation Voltage | Dip-Coated ≥6kV, Flame Retardant UL94 V0 |
| Tolerance | Linear ±0.1mm, Angle ±0.5° (can be adjusted) |
Customizable Cross-Section Types
We support all non-standard cross-section customization, common types include:
- L-shape: Suitable for right-angle connections, cabinet corners, space-saving installation
- T-shape: Used for shunt connections, multi-layer busbar integration, stable current distribution
- C-shape: Applied to slot-type connections, drawer cabinet contacts, easy to install and fix
- U-shape: For cladding connections, heat dissipation structures, strong corrosion resistance
- I-beam: Suitable for large-span, high-rigidity current-carrying scenarios
- Other Types: Z-shape, arc, stepped, multi-hole, irregular shape, etc.
Processing Technology
Cathode Copper → Melting & Casting → Continuous Extrusion → Precision Drawing → Fixed-Length Cutting → CNC Punching/Bending → Surface Treatment → Inspection & Packaging
- Forming Process: Continuous extrusion (high efficiency, dense structure), mold forming, CNC precision machining
- Dimensional Tolerance: Linear ±0.1mm, Angle ±0.5°, Length ±0.5mm (can be improved according to requirements)
-
Optional Surface Treatment:
- Bare Copper: With anti-tarnish oil, cost-effective, suitable for general indoor environments
- Tin-Plated: Anti-oxidation, easy to weld, extended service life
- Nickel-Plated: Corrosion resistance, high temperature resistance, suitable for harsh environments
- Dip-Coated/Powder-Coated: Insulation voltage ≥6kV, flame retardant (UL94 V0), good insulation performance
Application Fields
- Low & High Voltage Switchgear, Distribution Cabinets, Bus Ducts
- New Energy Industry: Energy Storage Systems, Photovoltaic (PV) Power Plants, Wind Power, EV Chargers, Battery Packs
- Rail Transit, Industrial Power Supplies, UPS, Inverters
- Large Motors, Generators, Transformers, Rectifiers
- Metallurgy, Electroplating, Chemical Industry and other high-current electrolysis scenarios
- Marine, Aerospace, Medical Equipment (high-precision requirements)
Ordering Information
1
Provide Drawings/Samples: Clearly mark cross-section size, length, hole position, bending angle, quantity and surface treatment requirements.
2
Minimum Order Quantity (MOQ): 5 piece (custom samples available)
3
Lead Time: 7–15 working days for regular orders; expedited service available for urgent orders.
4
Packaging: Moisture-proof film + carton/wooden box, effectively preventing scratches and oxidation during transportation.
Frequently Asked Questions
Q
What copper material grades are available for special shape copper busbars?
A
Our standard material is T2 Copper with a purity of Cu≥99.99%, which ensures excellent electrical conductivity of ≥58 MS/m at 20℃. Oxygen-free copper (OFC) is also available as an optional upgrade for applications requiring even higher purity and conductivity performance.
Q
Can you manufacture fully custom cross-section shapes beyond the standard L, T, C, and U profiles?
A
Yes. We support all non-standard cross-section customization. In addition to common profiles such as L-shape, T-shape, C-shape, U-shape, and I-beam, we can also produce Z-shape, arc, stepped, multi-hole, and fully irregular custom shapes. Simply provide your technical drawings or physical samples and we will manufacture accordingly.
Q
What surface treatment options are available, and which is best for outdoor or harsh environments?
A
We offer four main surface treatment options: Bare Copper (with anti-tarnish oil, ideal for general indoor use), Tin-Plated (anti-oxidation, easy to solder), Nickel-Plated (high corrosion and temperature resistance, best for harsh or outdoor environments), and Dip-Coated/Powder-Coated (provides insulation voltage ≥6kV with UL94 V0 flame retardancy). For outdoor or harsh industrial environments, Nickel-Plated or Dip-Coated finishes are strongly recommended.
Q
What is the minimum order quantity (MOQ) and what is the typical lead time?
A
The minimum order quantity is 5 pieces, and custom prototype samples are also available for evaluation purposes. Standard production lead time is 7–15 working days. If you have urgent requirements, please contact us in advance and we can arrange expedited production and delivery to meet your schedule.
Q
What dimensional tolerances can be achieved for custom special shape copper busbars?
A
Our standard dimensional tolerances are: Linear ±0.1mm, Angle ±0.5°, and Length ±0.5mm. These tolerances can be further tightened based on specific application requirements. For high-precision industries such as aerospace, medical equipment, or precision electronics, please specify your tolerance requirements in your drawing and we will confirm feasibility.
Q
What industries and applications are special shape copper busbars suitable for?
A
Special shape copper busbars are widely used across many industries, including low and high voltage switchgear, distribution cabinets, bus ducts, new energy systems (energy storage, PV power plants, wind power, EV chargers, battery packs), rail transit, industrial power supplies, UPS and inverters, large motors, generators, transformers, rectifiers, metallurgy, electroplating, chemical electrolysis, and high-precision sectors such as marine, aerospace, and medical equipment.