Bus bars are metallic strips or bars used to conduct electricity and distribute electrical power to various systems. They are commonly incorporated into panel boards, busway enclosures, and switchgears. At ESI, we manufacture custom bus bars for use in electrical applications across diverse industries.

To manufacture these products, we rely on the progressive die stamping process. This process utilizes a series of dies installed across multiple stations to progressively form bus bars into the desired size and shape with optimal speed and precision. Using this technique, we can deliver bus bars that are completely tailored to your unique application requirements.

Benefits of Custom Bus Bars

ESI can manufacture bus bars with full-round, square, or radius corner edges to suit various needs. In addition to enhancing power distribution, our custom bus bars offer the following benefits:

  • Cost-efficiency. After initial installation costs, customized bus bars offer a low total cost of ownership. This is because they eliminate the need for additional or outside electrical work.
  • Quick installation. Custom bus bars from ESI offer fast, safe installation with clean and organized wiring. Once they are installed, power is distributed without downtime or other interruptions.
  • Long-lasting. ESI’s custom bus bars provide long, dependable service with minimal maintenance requirements.
  • Environmentally friendly. Because bus bars are reusable and require fewer materials, they offer a more environmentally friendly solution compared to other power distribution options.

Copper vs. Aluminum

Copper and aluminum are both commonly used materials for producing bus bars. Although aluminum is often used to reduce manufacturing costs, it is not as conductive as copper. Conductivity is crucial to electrical and electronic operations, which is why ESI produces our bus bars from quality copper materials. Other advantages of using copper for bus bars include:

  • Resilience to higher temperatures to minimize short circuits
  • Long life span
  • Resistance to damage

ESI can also tin plate copper bus bars to enhance their solderability and corrosion resistance. While copper is typically the better choice for bus bars, we can use aluminum at the customer’s request.

Dedication to Quality

At ESI, we are dedicated to meeting our customers’ requirements and enhancing satisfaction through the continuous improvement of our products, processes, services, and quality management system. To illustrate our commitment to quality, we perform various testing and inspection procedures, including:

  • Failure Mode and Effects Analysis (FMEA) to prevent potential failure
  • Production Part Approval Process (PPAP) for strict compliance
  • Rigorous inspection processes via technology and Six Sigma Black Belt Trained QA team
  • Advanced Product Quality Planning (APQP) for production stability

We are also IATF 16949:2016 certified to ensure we deliver precise, high-quality products.

Get in Touch With ESI for Custom Bus Bars Today

Bus bars play a critical role in power distribution and storage systems. At ESI, we utilize progressive die stamping techniques to manufacture customized bus bars that meet your unique specifications. Our extensive experience and commitment to quality allow us to deliver precise, reliable bus bars at faster speeds and lower costs. For more information about our bus bar capabilities, or to get started on your custom bus bar solution, contact us or request a quote today.

Comments are closed

Ready to get started?

Please fill out this short form to request your quote.