1. What a busbar actually is
- Function: move hundreds (or thousands) of amps with minimum voltage drop and thermal rise.
- Geometry: flat, hollow, U-channel, laminated or flexible; rectangular, round, even elliptical—whatever fits the pack layout .
- Material stack: Cu-ETP for conductivity, Al 1060 for weight, Cu-Al clad for cost/performance sweet spot; PET, PI or epoxy powder coating for insulation .
2. Why metal stamping beats machining
Old way: saw ➜ mill ➜ drill ➜ tap = long cycle, chips everywhere.
Progressive-die way (our way):
- Feed precision strip up to 400 mm wide.
- Pierce, emboss, coin, form, tap in 12 stations at 200 spm.
- Part-off and inspect—±0.02 mm, zero secondary ops .
Result: 10× output, 30 % lower piece price, repeatable ampacity because grain flow is engineered into the bend radius.
3. Our in-house capabilities
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| Station | Spec |
|---|---|
| Press window | 1,500 mm bed, 200 T servo, 4-axis transfer |
| Tool steel | AISI M4/ASP 23, vacuum heat-treated to 62 HRC |
| In-die tapping | M2–M8, 500 rpm electric spindle, torque feedback |
| On-board vision | 0.01 mm repeatability, 100 % hole-check |
| Run rate | 2.5 M pcs / month on a single 2-shift pattern |
Die design? Done with AutoForm & Dynaform copper-flow modules—we see cracks before steel is cut.
4. Where China wins (and where it still chases)
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| Factor | China position | Global gap left |
|---|---|---|
| Tooling cost | 40–50 % vs EU/NA die quotes | High-strength Cu-Cr-Zr strip still imported |
| Cycle time | 7 days prototype, 21 days hardened tool | — |
| Laser post-process | Green-light 120 mm/s weld on 2 mm Cu | Swiss seam-tracking robots still faster on long seam |
| Laminated busbar | PCB-embedded layer stacks already in mass production | UL 94-V0 powder coating IP held by 2 EU players |
| Local market pull | 10 GWh+ battery plants within 300 km radius = instant feedback loop | — |
5. Real parts we ship every week
- 800 V SiC inverter busbar, 2 mm Cu, 3-D stamped, in-die M4 tapped holes, nickel pre-plate, Kapton window masked for laser weld.
- Pouch-cell “ear” jumper, 0.3 mm Cu-Al clad, 8-station progressive, selective form-down for ultrasonic weld clearance.
- Server-rack power distribution blade, Al 1060, epoxy powder coated, 1000 A continuous, weight down 38 % vs. copper only.
6. Sustainability & quality
- Scrap buy-back loop—Cu chips remelted to 99.95 % cathode, closed in 300 km radius.
- IATF 16949 & ISO 14001 certified plants, CpK ≥ 1.67 on critical dimensions, real-time SPC dashboard for customers.
7. Ready to spec your next busbar?
Send your STEP, DXF—or even a napkin sketch to Precise works +—we’ll return:
- DFM + die concept in 48 h
- Prototype blanks in 7 days
- PPAP Level 3 + IST ampacity report in 4 weeks
Get a 24-hour quote from China → Contact Us – preciseworksplus.com
From copper coil to current corridor—we tool it, we stamp it, we ship it.
