Special Shape Copper Busbar Processing

Special shape copper busbars are customized conductive profiles designed for non-standard electrical connection scenarios. Made of high-purity T2 electrolytic copper (Cu≥99.99%), they are manufactured through advanced continuous extrusion, precision forming and surface treatment processes.

We provide full customization services according to your drawings, samples or specific requirements, including cross-section shape, length, hole position, bending angle and surface treatment, perfectly adapting to narrow spaces, complex connection structures and high-current working environments.

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Product Details

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)