Custom Copper Busbars, PVC & PA11 Coating

Overview

We specialize in custom-made solid copper conductors and busbars for EV, Hybrid EV and battery systems. We also manufacture flexible braided copper connections.

Our production includes CNC laser and water-jet cutting, precision machining, polishing and high-quality insulation through PVC dip coating and PA11 powder coating technologies.

Products

Copper Bus Bars
Aluminium Bus Bars
Custom Fabricated Copper Bus Bars
Custom Copper Components
Copper Electrical Power Connectors
Tinned Copper Bus Bars
Insulated Copper Bus Bars
Grounding Bar & Kits
Grounding & Earthing Products

Battery Copper Connectors
Low Voltage Copper Bus Bar for Switchgear
Aluminium Busbar Connectors
Custom Flexible Bus Bars
Flexible Braided Copper Connectors
Earthing Braids
Copper Braids
Tinned Copper Braids

Custom PVC Dip-Coated Copper Busbars

PVC dip-coated busbars are copper conductors insulated with PVC plastisol coating. This provides reliable electrical insulation, environmental protection and long-term durability.

Key features & benefits:

Prevents short circuits, enhances operator safety
Moisture, dust, chemical resistance
Durable, seamless coating
Customizable shapes and sizes
Optionally tin or nickel plated

Technical specifications:

Alloy: Cu-ETP (CW004A)
Thickness: 1.5–5.0 mm (others on request)
Finishing: Tin / Nickel plating
Insulation: PVC Plastisol
Color: Orange (others on request)

PVC dipping process:

A preheated copper busbar is submerged into liquid PVC plastisol. Coating thickness depends on immersion time and withdrawal speed. After dipping, the part is cured to form a durable and uniform insulating layer.

Custom PA11 Coated Copper Busbars

PA11 (Polyamide 11) coated busbars use a bio-based polymer for electrical insulation and outstanding durability. PA11 is ideal for EV and high-current distribution systems.

Advantages of PA11 coating:

Electrical insulation (CTI > 600V)
High corrosion resistance
Excellent abrasion, impact & UV resistance
Improved safety & reduced electrical hazards
Flexible coating for compact busbar designs
Bio-based, sustainable material
Supports complex shapes & geometries

Technical specifications:

Alloy: Cu-ETP (CW004A)
Thickness: 1.5–5.0 mm (others on request)
Finishing: Tin / Nickel plating
Insulation: Polyamide 11 (PA11)
Color: Orange (others on request)

Fluidized-bed PA11 coating process:

A preheated copper part is dipped into a container of fluidized polymer powder. The powder melts and bonds to the metal surface. Afterward, the busbar is cured in an oven to create a continuous, highly durable insulating film.

Services

PVC dip coating
PA11 fluidized bed coating
Cutting (CNC laser & waterjet)
Punching
Bending
Milling
Drilling
Thread tapping
Copper brazing