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Direct-Factory Busbar Manufacturer for Copper, Laminated, and Flexible Busbar Solutions

 

Xiamen Apollo Stamping Welding Technology manufactures customized busbars for EV battery systems, energy storage equipment, power electronics, and industrial electrical applications. Our production integrates precision stamping, CNC machining, welding, and insulation processes using high-conductivity copper materials such as C1100 and T2 copper with conductivity up to 100% IACS.

 

Our engineering team supports drawing review, DFM optimization, and mass production with controlled dimensions, surface treatment options, and complete quality documents. From prototype development to high-volume supply, Apollo provides OEM busbar manufacturing based on customer electrical parameters, mechanical requirements, and PPAP Level 3 documentation.

 

Request a Factory Direct Quote

 

 

Explore Our Busbar Product Catalog

 

 

Select suitable Copper Busbars, Insulated Busbars, Laminated Busbars, Flexible Copper Foil, Flexible Braided Wire, and Aluminum Busbars solutions designed for high-current electrical connection systems

 

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Material Standards, Tooling & Forming Processes

 

 

Apollo busbars are manufactured according to electrical conductivity, thermal management, and mechanical strength requirements in EV, ESS, PV inverters, and industrial power systems.

 

For copper busbars, we commonly use C1100 pure copper and T2 electrolytic copper with high electrical conductivity. The copper material provides low-resistance current transmission and stable thermal performance under continuous high-current operation.

 

For laminated busbars, multiple copper layers are combined with PET, PI, or epoxy insulation films to shorten current paths and reduce electromagnetic interference. The optimized laminated structure helps reduce stray inductance in high-frequency switching applications such as SiC inverter systems.

 

For flexible busbar products, copper foil layers or braided copper structures provide mechanical flexibility for vibration compensation, thermal expansion absorption, and compact battery pack installation.

 

Apollo owns precision tooling capabilities, including progressive stamping dies, CNC machining, and controlled bending processes to achieve stable dimensional accuracy for customized busbar production.

 

Busbar Manufacturing Specifications

 

Parameter Specification
Copper Material C1100 / T2 Pure Copper
Copper Conductivity ≥100% IACS
Thickness Range 1 mm- 20 mm Custom
Surface Treatment Tin Plating / Nickel Plating / Silver Plating
Insulation Method PET Film / Epoxy Coating / Powder Coating
Machining Accuracy Tolerance ±0.01mm
High Voltage Insulation Dielectric Breakdown Voltage Testing
Application EV Battery, ESS, UPS, PV Inverter

 

 

Advanced Joining, Insulation & Surface Treatments

 

 

Busbar performance depends on reliable electrical connection and insulation protection. Apollo applies different joining technologies according to current density, mechanical load, and environmental conditions.

 

Copper busbars can be processed with laser welding, resistance welding, diffusion welding, and mechanical joining methods. For copper-to-aluminum applications, laser welding parameters are controlled to reduce brittle intermetallic compound formation and maintain mechanical strength.

 

For insulated busbars, Apollo provides PET laminated insulation, epoxy powder coating, and heat-shrink protection. Insulation materials are selected according to voltage rating, thermal conditions, and environmental requirements.

 

Typical insulation performance includes:

UL94 V-0 flame retardant materials

Dielectric breakdown voltage testing

Surface insulation resistance inspection

Environmental durability verification

 

Surface treatments including tin plating, nickel plating, and silver plating improve oxidation resistance and contact stability, especially for high-current applications exposed to humidity and temperature cycling.

 

Request Custom Technical Evaluation

 

 

Quality Control & Certifications at Apollo

 

 

Apollo applies a complete quality management system from incoming material inspection to final shipment verification.

 

Copper material composition is checked before production. During manufacturing, dimensional inspection is performed using CMM measuring equipment, optical image measurement systems, and process monitoring methods.

 

For customized busbar projects, Apollo supports PPAP Level 3 documentation including:

Process Flow Diagram

PFMEA

Control Plan

Material Certification

CPK Process Capability Report

 

Final inspection includes:

CMM measurement accuracy up to 0.0007mm

Electrical conductivity testing

Temperature rise testing

High voltage withstand testing

Insulation resistance testing

Mechanical strength verification

Apollo production follows ISO 9001 and IATF 16949 quality management requirements to support automotive and new energy supply chains.

 

 

Frequently Asked Questions

 

 

Q: What copper material is suitable for EV battery busbars?

A: C1100 and T2 pure copper are commonly selected for EV battery busbars because they provide high conductivity, stable thermal performance, and good welding characteristics. Apollo can supply customized copper busbars according to current rating, installation space, and connection requirements.

Q: How does laminated busbar design reduce stray inductance?

A: Laminated busbars place positive and negative conductors close together with insulation layers between them. This structure reduces current loop area and helps achieve low stray inductance designs, including applications requiring less than 10nH.

Q: What dimensional tolerance can Apollo achieve for custom busbars?

A: Apollo supports precision busbar machining with controlled tolerances down to ±0.01mm depending on material thickness, forming structure, and inspection requirements. CMM and optical measurement equipment verify production consistency.

Q: Can Apollo provide insulated busbars for high-voltage systems?

A: Yes. Apollo supplies insulated busbars using PET film, epoxy coating, and other insulation solutions. Products can be tested for dielectric breakdown voltage, insulation resistance, and environmental durability according to customer specifications.

 

 

Custom Busbar Manufacturing Support from Apollo

 

 

Send your 2D/3D CAD drawings (.STEP, .DWG) or electrical specifications to the Apollo engineering team. We provide free DFM analysis, material selection suggestions, and manufacturing evaluation within 24 hours.

 

With in-house stamping, welding, machining, and insulation capabilities, Apollo supports prototype development and stable mass production for EV, ESS, PV inverter, and industrial electrical applications.

 

Submit Your Busbar Drawing & Get Engineering Review

We're well-known as one of the leading busbar manufacturers and suppliers in China. Please feel free to buy high quality busbar at competitive price from our factory. For more information, contact us now.

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