Braided Copper Busbar

Choose a braided busbar when the connection must move, flex, or absorb vibration during operation. The woven wire structure allows bending and twisting in any direction without fatigue cracking — something a laminated foil stack cannot do. Typical triggers: moving parts inside switchgear, connections bridging vibrating motors or compressors, flexible links between bus sections that expand and contract thermally, and any joint that must be routed around obstacles at installation. If the joint is static and current density is the priority, a laminated busbar is the better fit.

Finer wire (0.05mm–0.10mm) produces a softer, more compliant braid with better fatigue life under repeated flexing — preferred for high-cycle dynamic applications. Coarser wire (0.15mm–0.2mm, our standard) gives a stiffer braid with higher current capacity per cross-section and lower DC resistance, suited to connections that flex occasionally rather than continuously. We offer 0.05mm, 0.07mm, 0.10mm, 0.12mm, 0.15mm (standard), and 0.2mm — specify based on your flex frequency and current requirement.

We supply four standard terminal configurations: ferrules (crimped tube ends for busbar-to-busbar connections), lugs (flat drilled pads for bolted joints), welded ends (solid copper blocks fused to the braid for maximum conductivity), and insulated versions of the above where the braid body must be electrically isolated. Custom terminal shapes, hole patterns, and offset angles are available on request.

Please specify: Length (L) × Width (W) × Thickness (T), cross-sectional area, connector shape and hole type, hole diameter (d), and wire diameter (default 0.15mm). For non-standard geometries — shaped terminals, angled ends, multi-branch configurations — a drawing or sample is welcome. We support both prototype and high-volume production.

Braided copper busbars are the standard solution for medium and low voltage circuit breakers, high and low voltage switchgear, vacuum contactors, electric and diesel locomotives, mining flameproof switches, automotive battery connections, and any non-horizontal moving part carrying current. If the equipment vibrates, moves, or requires a flexible electrical bridge, a braided busbar belongs in the design.

PVC is the standard choice for indoor, ambient-temperature applications — cost-effective and easy to terminate. TPE offers better flexibility at low temperatures and improved chemical resistance. Silicone handles continuous high-temperature environments up to 180°C and beyond, and remains flexible even after prolonged heat exposure. Specify the operating temperature range and any chemical exposure and we will recommend the appropriate insulation grade.