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Busbars

Busbar manufacturing requires unique capabilities and experience.  Our full understanding and expertise in dealing with red metals and aluminum materials plus our existing partnerships with approved secondary suppliers allows us to provide you with a more finished product that meets your exact requirements.

Busbar Applications

As demand for electric vehicles has exploded in recent years, we have been adding new technical capabilities to produce custom busbars to transmit power in all types of electric vehicles, whether hybrid, all-electric, or autonomous (self-driving).

Custom metal stamped busbars of different sizes and complexities are required to transmit current from high-powered battery packs to a variety of electrical applications including:

  • Sunroofs
  • Sensors
  • Communications
  • Windows
  • Remote Controls

Busbar Types

  • Personal Computers and Electronics
  • Surge Protection Devices
  • Renewable Energy and Line Energy
  • Electrical Panels
  • Single and Multi-Conductor Batteries

Busbar Materials

  • Copper
  • Bronze
  • Aluminum

Busbar Services

We provide comprehensive services to take busbar designs from concept to completion.

  • Prototyping
  • Design Assistance
    (material selection, dimensions, tolerance, optimal performance at lowest cost)
  • Tool Design & Build
  • Automated Assembly

Finishing Services

  • Hardware Insertion
  • Complex Busbar Bending
  • Insulators
  • Epoxy and E-Coating
  • Metal Plating
  • Plastic Injection Molding and Overmolding
  • Welding
  • Deburring and Cleaning

Quality

We are committed to mistake-proof processes. You can rely on us, as we have one of the industry's largest and most experienced engineering, design, and tool & die teams with more than 60 industry experts and craftsmen.

REQUEST A QUOTE FOR A CUSTOM BUSBAR TOOL

Prototype or Production Tool
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Busbar Insights

View All Posts
rigid-busbars
June 14, 2024
Rigid Busbars Reign Supreme in EVs

Busbars: The Lifeline of Electric Vehicles Before we discuss why rigid busbars are superior to flexible busbars, it's crucial to grasp the ...

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busbars-copper-vs-aluminum
April 19, 2022
Copper vs Aluminum Busbars — Which Is Right for Your Project?

There is some debate regarding which material is better for use for busbars—aluminum or copper. Both materials have been used with success, but which ...

Learn More
busbars
October 7, 2020
Growth in Electric Vehicles Driving Need for Metal Stamped Busbars

Demand is revving up for electric vehicles of all kinds, from cars to trucks to public transport. According to Bloomberg NEF market forecasts, ...

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820 W. Algonquin Road
Algonquin, IL 60102-2486
Tel: 847-658-5041
Fax: 847-658-9150
Email: sales@kenmode.com
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