Custom Shape Copper Busbar

Henan Gnee New Material Co., Ltd. is one of the most professional manufacturers and suppliers of custom shape copper busbar in China, specialized in providing high quality copper products with competitive price. Welcome to buy discount custom shape copper busbar for sale here from our factory. Customized orders are welcome.

A bent copper busbar is a copper conductor that has been formed into a non-straight shape – such as L-shape, Z-shape, U-shape, or multi-bend profiles – to fit specific enclosure layouts or connection points. Unlike standard flat busbars that run in straight lines, bent busbars change direction to route power around obstacles, connect components at different levels, or save space inside crowded panels.

Common shaped for this product：

L-shaped copper busbar

Z-shaped copper busbar

U-shaped copper busbar

Offset copper busbar

Formed copper busbar

Standard straight busbars cannot reach terminals that are not aligned on the same plane. Custom shape copper busbar solves this by bending to match your exact connection points.

L-Shape, Z-Shape and U-Shape copper busbar cover more than 80% of custom shape requests. For complex geometries with multiple bends or twists, we also offer CNC formed busbars with custom tooling.

Not sure which shape you need? Send us a photo of your panel or a sketch of your connection points. We will recommend the optimal shape.

Custom shape copper busbar is used in applications where straight busbars cannot fit or connect properly.

Typical applications：

A customer needed to connect a main breaker to three branch breakers located at different heights and offsets. Using straight busbars would require five separate pieces and jumper cables. A single Z-shaped copper busbar replaced all five connections – saving space and reducing failure points.

The minimum bend radius for copper busbar is critical. Bend too tight and the copper may crack, weaken, or experience reduced conductivity at the bend.

Recommended Minimum Bend Radius

Minimum bend radius for copper busbar depends on material grade and thickness. C10100 (oxygen-free) is slightly less ductile than C11000 and requires a larger bend radius. For production orders, we recommend testing a sample before committing to large quantities.

General rule：

Thickness ≤ 6mm：Bend radius = 2x thickness (minimum)

Thickness > 6mm：Bend radius = 2.5x to 3x thickness

Always bend across the width (easy), never bend across the thickness (difficult, high crack risk)

C11000 vs C10100 for custom shape busbar – for 90% of bent busbar applications, C11000 is the better choice. It bends more easily, costs less, and performs perfectly in standard electrical panels. Only choose C10100 if your application specifically requires oxygen-free copper.

For bent busbars in switchgear, MCCs, and battery packs – use C11000. Save C10100 for special applications.

1. Eliminate jumper cables
Instead of using five short cables to connect offset terminals, one Z-shaped busbar does the job. No lugs, no crimping, no loose connections.

2. Save panel space
Bent busbars route around components instead of requiring extra clearance for straight paths. You can pack more into the same enclosure.

3. Reduce connection points
Every connection is a potential failure point. A bent busbar has no connections between the two ends – just the solid copper bar.

4. Improve heat dissipation
A solid copper busbar carries heat away from terminals better than a cable. The bend does not reduce thermal performance significantly.

5. Cleaner installation
Field electricians prefer bent busbars. No measuring, cutting, or crimping cables on site. Just bolt it in place.

One customer replaced 12 jumper cables (12 lugs, 24 crimps, 24 bolts) with two Z-shaped busbars (4 bolts total). Labor time dropped from 2 hours to 15 minutes.

Not sure if your bend is feasible?-Free design check

Custom Fabrication Capabilities

Bending and punching for non-standard copper busbar is done on CNC press brakes with custom dies. We recommend keeping holes at least 10mm away from bend lines to prevent distortion. Plating is always applied after all fabrication steps.

Every custom shape busbar is inspected on a CMM (coordinate measuring machine) before plating. We provide a dimensional inspection report with each shipment.

For most bent busbars, tin plating without insulation is sufficient. If the busbar is in a touch-safe panel, heat shrink on straight sections is fine. For outdoor or high-voltage applications, specify epoxy coating.

Yes and no. Here is how tooling cost for custom copper busbar works.

Is there a tooling fee for custom shapes? For simple L-shapes and Z-shapes with standard tooling – no fee. For unique shapes requiring custom dies – small fee, refundable upon production order.

Sample available – Request a custom shape sample. We will make 1-2 pieces from your drawing.

How to package bent copper busbars for shipping – we use foam inserts that match the exact shape of your busbar. This prevents bending or twisting during sea freight. For air freight, heavy-duty cardboard with internal foam is usually sufficient.

Q1：What is the MOQ for custom shape copper busbar?

For simple shapes (L-shape, Z-shape, U-shape with standard bend radius)： MOQ = 50 pieces per size.

For complex shapes (3+ bends, tight tolerances, or custom tooling required)： MOQ = 100 pieces per size.

For sample orders (any shape, any size)： No MOQ. We support small-batch prototype orders before mass production.

Simple shapes include：90° L-bend, Z-step offset, U-bend with standard radii (2x thickness).

Q2：Do you provide samples of bent copper busbar?

Yes. Sample cost depends on shape complexity.

For simple shapes (L, Z, U with standard bend)： Sample fee = 50 USD. Lead time = 7-10 business days.

For complex shapes (3+ bends or custom tooling)： Sample fee = 100-200 USD. Lead time = 10-15 business days.

Sample fee is fully deductible from your first production order of 500 pieces or more.

Q3：What is the minimum bend radius for copper busbar?

For C11000 (ETP copper – most common)：

Thickness ≤ 6mm：Minimum bend radius = 2x thickness (e.g., 6mm thick = 12mm radius)

Thickness > 6mm：Minimum bend radius = 2.5x to 3x thickness (e.g., 10mm thick = 25mm radius)

For C10100 (oxygen-free copper)： Add 25-50% to the above values.

Tighter bends may cause cracking or reduced current carrying capacity. We will review your drawing and advise.

Q4：Can you punch holes on bent areas of copper busbar?

Not recommended. Holes placed on or within 10mm of a bend line may distort during bending or crack in service.

Best practice： Place all holes at least 10mm away from the bend start line.

Q5：What are the tolerances for bending and hole punching?

Q6：Is there a tooling or mold fee for custom shapes?

For simple shapes (L, Z, U with standard bend radii)：No tooling fee. We use existing dies.

For complex shapes requiring custom dies： Tooling fee = 50 - 150 USD one-time fee.

The tooling fee is fully refundable when you place a production order of 500 pieces or more. Custom dies are kept on file for future reorders at no additional cost.

Q7：What is the lead time for custom shape orders?

Sample orders (1-10 pieces)： 7-10 business days for simple shapes, 10-15 days for complex shapes.

Production orders (50-500 pieces)： 15-20 business days for simple shapes, 20-25 days for complex shapes.

Production orders (500+ pieces)： 20-25 business days. Expedited service available – add 30% rush fee to reduce lead time by 30-40%.

Q8：Sea freight vs air freight – cost and time difference for custom busbars?

Q9：Can you make copper busbar with multiple bends (more than 3 bends)?

Yes, up to 6 bends on a single busbar. Multi-bend busbars are common in EV battery packs and compact switchgear.

Each additional bend increases tooling cost and lead time. For complex multi-bend shapes, please send a 3D model (STEP or IGES) for feasibility review.

We can also produce 3D formed busbars with bends in different planes (not just flat). Contact us with your drawing.

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