Overview
Our Custom High-Stability Progressive Stamping Copper-Alloy Busbars with Riveting Pressure Service Solution are engineered for robust electrical distribution in EV battery packs, power electronics, telecom racks, and industrial power modules. Built from high-conductivity copper alloys and produced via precision progressive stamping, CNC secondary forming, and controlled riveting/clinching assembly, these busbars deliver excellent electrical reliability, mechanical stability, and repeatable performance in high-vibration and high-current environments. Turnkey services include prototyping, toolmaking, automated progressive stamping, rivet-press assembly, plating, and full electrical/thermal validation to meet demanding OEM specifications.
Basic Information
| Attribute | Details |
|---|---|
| Place of Origin | Xiamen, China |
| Brand Name | OEM / Private Label |
| Product Type | Progressive-Stamped Copper Alloy Busbar with Riveted Assembly |
| Material | C11000 / C10100 / Cu-ETP / Custom copper alloys |
| Thickness Range | 0.10 – 6.00 mm (custom) |
| Width Range | up to 300 mm (custom) |
| Tolerance | ±0.01 – ±0.05 mm (per drawing) |
| Surface Finishing | Tin, Nickel, Silver, Gold, or custom electroplating |
| Assembly | Cold riveting, clinch riveting, resistance spot welding, press-fit inserts |
| Operating Temp | -40 °C to +150 °C (application dependent) |
| Certifications | ISO 9001, IATF 16949; ROHS / REACH declarations; UL options available |
| MOQ | Small orders accepted |
| Sample Lead Time | 5–7 business days |
| Production Lead Time | 15–30 business days |
| Packaging | Standard export or customer-specified |
Key Features & Benefits
- Progressive Stamping Precision: Multi-station progressive dies produce complex geometries, integrated bending, and formed features in a single progressive feed for consistent dimensional control and high throughput.
- High Mechanical Stability: Riveted pressure assembly (clinch riveting or cold riveting) and optional spot-weld reinforcement provide superior joint strength and vibration resistance for automotive and industrial duty cycles.
- Electrical Performance: High-conductivity copper alloys, tight tolerances, and controlled plating deliver low contact resistance, excellent current carrying capacity and reliable thermal performance.
- End-to-End OEM Service: In-house toolmaking, prototype validation, automated stamping lines, rivet-press stations and finishing enable rapid design iterations and scalable production.
Surface Finishing Options
- Tin Plating: Excellent solderability and corrosion resistance for battery and connector interfaces.
- Nickel Plating: Hard, wear-resistant finish for harsh environments and improved solder/leaching protection.
- Silver Plating: Superior conductivity and low contact resistance for high-performance connections.
- Gold Plating: Premium corrosion resistance and stable long-term contact for sensitive applications.
- Passivation / Clear Coating: For improved oxidation resistance while preserving conductivity.
Manufacturing & Assembly Process
- Material Prep: Certified electrolytic copper alloys cut to strip specifications with XRF material verification.
- Progressive Die Stamping: Multi-station progressive dies stamped on high-speed presses with in-die forming for holes, slots, and emboss features.
- Secondary CNC Forming: Bending, flaring, trimming and hole reaming performed on CNC brakes and automated cell to hold ± tolerances.
- Riveting / Clinching: High-precision rivet presses and clinching machines apply controlled riveting pressure and cold heading to assemble inserts, spacers, or laminated layers. Optionally reinforced by resistance spot welding or laser welding.
- Surface Finishing: Electroplating in controlled baths; plating thickness and adhesion monitored per spec.
- Inspection & Testing: Dimensional, mechanical and electrical tests performed before packaging.
Quality Assurance
We run a full QA program to ensure every busbar meets specification: incoming material XRF verification, in-process load/force monitoring on stamping presses, dimensional inspection with ZEISS CMM and 3D laser scanners, plating thickness by XRF, contact resistance by four-point probe, and thermal cycling / ampacity validation under simulated load conditions. Mechanical strength of riveted joints is validated via pull/torque tests and vibration testing. All batches are serialized for full lot traceability and supplied with material & test certificates.
Applications
- EV battery interconnects and module busbars
- Power distribution blocks in energy storage systems
- High-current connectors in chargers and inverters
- Telecom and industrial power distribution panels
Why Choose Us?
- Full in-house vertical capability: tooling, progressive stamping, rivet assembly and plating.
- Proven traceability and testing for high-reliability power systems.
- Flexible production from small runs to high volumes with fast prototyping support.
- Engineering support for ampacity, thermal management and mechanical integration.
Factory
Our manufacturing campus combines 25 high-performance punch and stamping presses (30–300 tons), precision progressive die capability, CNC bending & forming cells, rivet-press and clinching stations, precision wire EDM and grinding, and controlled electroplating lines to deliver turnkey busbar fabrication from prototype to volume. Automated inspection—ZEISS CMMs, 3D laser scanners, four-point conductivity meters and XRF analyzers—supports rigorous ISO 9001 and IATF 16949 QA protocols, while specialized welding, ultrasonic cleaning, and automated assembly lines ensure cleanliness and consistent joint integrity for demanding automotive and industrial applications.
