Custom Copper Insulated Busbar with Nickel Plated

This insulated bus bar is made from rigid T2 / Cu-ETP copper, a material widely used for electrical busbars because of its high conductivity and suitability for formed power conductors.

The part is precision formed into a custom multi-bend geometry, nickel plated to 5–10 μm as specified, and coated with orange insulation while leaving the drilled terminal areas exposed for bolted electrical connection.

This insulated bus bar uses a rigid T2 copper conductor formed into a custom geometry for routing through compact or complex electrical assemblies. Precision bending creates the required offsets, while 5–10 μm nickel plating protects the copper surface. The conductor body is covered with orange insulation, leaving drilled metal terminals exposed for bolted electrical connection.

The part is suitable for conductive interconnection in EV battery packs, energy storage systems, power distribution cabinets and inverters. Its custom-formed geometry supports OEM projects requiring specific routing, terminal positions and installation clearances while maintaining a rigid copper current path.

Key applications:

EV battery packs, energy storage systems, inverters and power distribution equipment requiring a rigid conductive path with defined routing and terminal locations.

The selected category is Insulated Bus Bar because the conductor is a solid rigid copper busbar with an external insulation layer, rather than a laminated, flexible, CCS integrated or overmolded construction.

This also matches the manufacturer’s own distinction between insulated busbars and other busbar categories.