Copper-to-aluminum busbar combines copper’s conductivity and stability with aluminum’s weight and cost advantages. This custom busbar' structure offers low contact resistance and high energy efficiency. It is widely used in automation, metallurgy, power systems, and is especially vital in EV battery packs and high/low voltage equipment—delivering a reliable and cost-effective solution for modern energy applications.
The development of copper-aluminum composite busbars aims to address the inherent conductivity weaknesses of aluminum busbars. Aluminum is a softer material with faster creep rates, leading to loosening over time. Additionally, prolonged use increases surface contact resistance, resulting in electrical degradation and potential loss of conductivity.
Copper-aluminum busbars ensure safety, reliability, and longevity while significantly reducing costs. Testing shows a fundamental difference in electrical performance compared to aluminum busbars, offering much longer service life and higher reliability, with safety on par with copper busbars. Furthermore, copper-aluminum busbars are lighter, easier to install, and experience less bending stress from their own weight, making them a highly cost-effective solution.
Produced by innovative patent technology——Solid-Liquid machining processing technique to bond copper and aluminum permanently and firmly;
With higher electric conductivity: Can reach more than 98% of the same volume conductivity of pure copper;
| Plating Options: | Nickel Plating Silver Plating Tin Plating |
| Insulated Finishes: | PE, PVC, PA12, PET and Epoxy Powder Coating
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| Edge: | Full Round Edges Rounded Corners Square Corners |
| Voltage Type: | AC DC |
| Production Capabilities: | Bending Brazing Drilling Forming Milling Plating Punching Sawing Tapping Riveting |
| Industries Served: | Aircraft Automotive Electrical Switch Gear |
| Engineering Capabilities: | Design Assistance Design Verification |
| File Formats Accepted: | JPG DWG DXF |
Advanced Manufacturing
With 20+ years of experience in insulated dipping and automated processes—including robotic dipping, welding, and copper forming—RHI leverages cutting-edge technology to ensure high efficiency, precision, and product consistency.
Integrated Production
From raw material processing to mold and fixture fabrication, all critical steps are completed in-house—except for plating, which is handled by a certified nearby partner—ensuring full process control and quality traceability.
Responsive Support
We respond within 8 hours and offer on-site technical support within 24 hours in China (lead time may vary for overseas support), ensuring fast resolution for customer needs.
Agile Prototyping
Thanks to a streamlined supply chain and flexible production setup, we can deliver small batches quickly to accelerate early-stage development and validation.
Quality Assurance
We use certified ETP-grade copper, conduct 100% inspection before shipment, and comply with ROHS, REACH, UL94 V-0, ISO14001, and IATF16949 standards to meet global quality and safety requirements.
On-Time Delivery
With a skilled workforce, robust capacity, and reliable logistics, we consistently meet tight delivery schedules—even for high-volume or customized orders.
Cost Advantage
Our vertically integrated operations and manufacturing base in China allow us to offer competitive pricing without compromising quality or service.
