Product Description
A custom profile copper busbar is a shaped, variable-cross-section conductor - typically stepped like stair steps - where thickness is not uniform along the length. One section stays thick to carry high current, while another is thinner to suit bending, mounting or a tight space. This variable cross-section balances current-carrying needs against assembly room in a way a uniform flat bar cannot. Because the thickness changes along the part, we machine in multiple passes: the thick section is cut to an intermediate size first, then to final dimension, with each pass depth calculated so the step transitions stay in tolerance. Material is T2 copper to GB/T5585.1-2026, Cu >= 99.90%, >= 97.3% IACS.
A stepped profile is only as good as its transitions, and the risk with highly shaped profiles is discovering mid-order that a feature cannot be machined reliably. Our approach is to surface that boundary up front: during drawing review we assess the step geometry and tell you honestly which multi-stage structures we can hold to tolerance and which need redesign, rather than accepting the order blindly. We then machine in controlled passes and measure after each step. The buyer benefits two ways - feasibility is settled before you commit material, and the step thicknesses land as drawn, with a pre-production sample confirmed before bulk cutting.
Specifications
|
Parameter |
Specification |
|
Material Grade |
T2 Copper |
|
Copper Purity |
Cu ≥ 99.90% |
|
Standard |
GB/T5585.1-2026 |
|
Electrical Conductivity |
≥ 97.3% IACS |
|
Resistivity (20°C) |
≤ 0.0177 Ω·mm²/m |
|
Density |
8.9 g/cm³ |
|
Tensile Strength |
220–260 MPa |
|
Yield Strength |
≥ 170 MPa |
|
Hardness |
65–90 HV |
|
Elongation |
≥ 17% |
|
Step Thickness Transitions |
Custom per customer drawings |
Applications
Application 1 - Variable-cross-section conductive connections. The thick section carries the main current while the thin section is shaped for bending or fixing, so one bar handles both duty and mounting without adding adapters.
Application 2 - Space-constrained equipment. Where the enclosure only leaves room for a thin section in one area, material is removed exactly where it is not needed, keeping the conductor compact without sacrificing current capacity where it matters.
Application 3 - Special-shaped terminals and mixed mounting conditions. Stepped profiles adapt to terminals that demand different thicknesses along the same conductor, matching bolts, clamps and insulation clearances in a single formed part.
Customization
Produced from customer CAD drawings or 3D files, with step thicknesses, transition positions, bend angles, hole positions and overall dimensions defined per project. For complex multi-step or multi-surface structures we communicate the processing boundary up front and make a pre-production sample for your approval before bulk cutting. Mixed specifications are allowed in one order, and OEM branding is supported.
Packaging & Transportation
Wrapped with bubble film and bundled to protect the stepped profile edges; long or heavy parts are secured on solid wooden pallets. We support factory pickup and nearby-port delivery under EXW or FOB terms.
FAQ
Q1. My profile is very complex - will you take the order without checking feasibility?
No. We review the step geometry and bending drawings first and tell you honestly which structures we can hold to tolerance; highly complex multi-surface shapes are discussed up front, and a pre-production sample is confirmed before bulk production.
Q2. What is the MOQ, and can several profiles share one order?
The MOQ is 1000 kg, and multiple specifications can be mixed in a single order. Raw material is kept in stock so scheduling starts as soon as the order is placed.
Q3. How do you control dimensions across multiple machining passes?
We set the CNC program from your drawing and measure dimensions after each machining pass, with a visual inspection for obvious surface defects before packing. Third-party material inspection is fully accepted.
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