Precision cutting to your exact length
We offer precision cut-to-length services for all C11000 copper busbars. You specify the exact length, and we cut it with a tolerance of ±0.5mm. No more trimming on site – your busbars arrive ready to install.
Cutting capabilities:
| Parameter | Capability |
|---|---|
| Maximum length | 6,000 mm (single piece) |
| Minimum length | 50 mm (custom short pieces) |
| Thickness range | 3 mm – 30 mm |
| Width range | 10 mm – 250 mm |
| Cutting tolerance | ±0.5 mm |
| Cut surface | Deburred – no sharp edges |
In switchgear assembly, every millimeter counts. A busbar that is 2mm too long will not fit between components. A busbar that is 2mm too short leaves exposed copper and poor contact area. Our ±0.5mm tolerance eliminates these fitment issues.
Order custom cut C11000 copper busbar – just tell us your required length.
Professional hole punching and drilling
We offer precision hole punching and drilling for all standard hole shapes and sizes. Our high-precision CNC punching press delivers consistent accuracy across hundreds or thousands of pieces.
Hole types available:
| Hole Type | Size Range | Tolerance | Best For |
|---|---|---|---|
| Round holes | 4 mm – 20 mm diameter | ±0.1 mm | Standard bolted connections |
| Slotted holes | 6×12 mm up to 10×25 mm | ±0.15 mm | Adjustable mounting, thermal expansion |
| Counterbored holes | Custom sizes | ±0.1 mm | Flush bolt heads (clearance needed) |
| Threaded holes | M4 – M12 | ±0.1 mm | Direct bolt attachment (no nut needed) |
Hand-drilled holes are rarely perfectly positioned or perfectly round. Our CNC punching ensures every hole is exactly where your drawing specifies – within 0.1mm. Your bolts slide in easily, no filing or reaming required.
Professional bending for L, Z, U, and custom shapes
We offer precision bending for L-shape, Z-shape, U-shape, and custom angle busbars. Our high-precision CNC press brake ensures consistent angles across your entire order.
Bending shapes available:
| Shape | Description | Typical Use |
|---|---|---|
| L-shape (90° bend) | Single 90° bend at one end | Connecting components on different planes |
| Z-shape (offset) | Two opposite 90° bends | Stepping around obstacles |
| U-shape | Two parallel 90° bends | Wrapping around components |
| Custom angles | Any angle from 0° to 180° | Non-standard layouts |
| Multi-bend | 3-6 bends per piece | Complex busbar routing |
Bending capabilities:
| Parameter | Capability |
|---|---|
| Maximum busbar thickness for bending | 15 mm |
| Maximum busbar width | 120 mm |
| Maximum length after bending | 600 mm (bent section) |
| Bend angle tolerance | ±1° |
| Inside bend radius (minimum) | 1.5× thickness (annealed) / 3× thickness (half-hard) |
We stress-relieve bent busbars after fabrication to prevent spring-back and reduce internal stresses. This ensures your bent busbars maintain their shape during shipping and installation.
Tight tolerances
We hold all custom fabricated busbars to tight tolerances. Here are our standard guarantees:
| Feature | Tolerance | Measurement Method |
|---|---|---|
| Cut length | ±0.5 mm | Precision ruler or CMM |
| Width (standard sizes) | ±0.1 mm | Micrometer |
| Thickness | ±0.1 mm | Micrometer |
| Hole diameter | ±0.1 mm | Pin gauge or CMM |
| Hole position | ±0.2 mm | CMM or optical comparator |
| Bend angle | ±1° | Protractor or CMM |
| Overall length after bending | ±1.0 mm | Tape measure or CMM |
| Flatness (unbent sections) | 0.5 mm per meter | Straight edge + feeler gauge |
These tolerances meet or exceed ASTM B187 requirements. Most switchgear and panel builders find these tolerances sufficient for direct installation without rework.
Need tighter tolerances? Contact us.
Affordable fabrication with transparent pricing
Fabrication costs are charged per operation, not as a percentage of material cost. Here is our typical pricing structure:
| Service | Typical Charge | Notes |
|---|---|---|
| Cut to length (custom) | $0.50 – 1.00 per cut | Waived for orders over 500 pieces |
| Hole punching (per hole) | $0.20 – 0.50 per hole | Lower per hole for high quantities |
| Slotted holes | $0.50 – 1.00 per hole | More tooling time |
| Bending (per bend) | $1.00 – 3.00 per bend | Based on thickness and angle |
| Deburring | Included (no charge) | All edges deburred standard |
| Setup fee | $50 – 100 per order | One-time per unique part number |
| Drawing/engineering | $50 – 150 per drawing | Waived for orders over 100 pieces |
Example cost calculation for 100 pieces of custom busbar:
- Material: 100 × 2kg × $8.50/kg = $1,700
- Cut to length (100 cuts @ $0.50) = $50
- Hole punching (400 holes @ $0.25) = $100
- Bending (100 bends @ $1.50) = $150
- Setup fee = $50
- Total fabrication charge = $350
- Total order = $2,050 ($20.50 per piece)
Our in-house fabrication shop
Key fabrication equipment:
| Equipment | Brand / Type | Capability |
|---|---|---|
| CNC shearing machine | Industrial heavy-duty | Thickness up to 30mm, width up to 250mm, length up to 6,000mm |
| CNC punching press | High-precision industrial grade | Hole tolerance ±0.1mm, thickness ≤10mm, maximum 60 holes per minute |
| CNC drilling center | Industrial grade | For busbars >10mm thick, hole diameters 4-25mm |
| CNC press brake | High-precision industrial grade | Bending length up to 3,000mm, ±1° tolerance, 150 ton capacity |
| CNC bending machine | Industrial grade | For complex multi-bend parts |
| Deburring station | Manual + mechanical | All edges deburred standard |
| CMM inspection | High-precision coordinate measuring machine | Dimensional verification for first article and batch sampling |
FAQ
What is the maximum length you can cut copper busbar to?
6,000 mm (6 meters) as a single piece. That is our standard maximum due to handling and transportation constraints. For applications requiring longer continuous runs, we recommend using splice kits or multiple sections with jumper connections. We can also design and supply the splice kit for you.
What is the minimum hole diameter you can punch?
4 mm diameter for round holes. Below 4mm, the punch tool becomes too fragile for copper busbar thicknesses above 3mm. For holes smaller than 4mm, we recommend drilling instead of punching (drilling is available but costs more per hole).
Can you bend copper busbar without cracking it?
Yes – if you follow minimum bend radius guidelines. For annealed (soft) C11000 busbar, minimum inside bend radius is 0.5× thickness. For half-hard (H02) busbar, minimum is 1.5× thickness. For hard (H04) busbar, bending is not recommended – it will crack. We recommend ordering annealed or half-hard temper for any parts requiring bending.
What is your standard lead time for custom fabrication?
15-20 business days for typical orders. Breakdown: Drawing review (1-2 days), material preparation (3-5 days), fabrication (5-7 days), inspection (1-2 days), packaging (2-3 days). For urgent orders, we can expedite to 10-12 business days for an additional 15-20% rush fee. For very large orders (>1,000 pieces), lead time may extend to 25-30 days.
Do you provide drawings or CAD files for fabricated busbars?
Yes – we can create drawings from your sample or sketch. If you have an existing busbar but no drawing, mail us the sample. We will measure, create a CAD drawing, and send it to you for approval. Drawing fee is $50-150 depending on complexity – waived for orders over 100 pieces.
Can you fabricate busbars based on my sketch or sample?
Yes – we accept hand sketches, photos with measurements, physical samples, and CAD files. For hand sketches: please include all dimensions (overall length, hole positions, hole diameters, bend angles). For physical samples: we will measure, create a drawing, send for your approval, then fabricate to match. Sample return shipping is your cost.
Do you offer deburring and edge rounding?
Yes – deburring is standard at no charge. All cuts, punched holes, and sheared edges are deburred before shipping. Edge rounding (radius edges) is available for an additional charge – this is recommended for high-voltage applications (>600V) to reduce corona discharge and for applications where workers frequently handle the busbars.
Can you combine fabrication with plating?
Yes – fabrication first, then plating. The correct sequence is: cut → punch → deburr → bend → then plate (tin/silver/nickel). This ensures the plating covers the cut edges and hole interiors – not just the original surface. If you plate first and then fabricate, the cut edges will be bare copper and exposed to corrosion. Always specify your finish requirements when ordering fabrication.
What is the MOQ for custom fabricated copper busbar?
50 pieces for custom sizes, 10 pieces for standard sizes, and no MOQ for samples. Standard sizes (from our standard width/thickness library) can be fabricated with 10-piece MOQ. For completely custom dimensions (width, thickness, length not in our standard list), MOQ is 50 pieces. Samples (1-5 pieces) have no MOQ – we support prototype orders before mass production. Sample fee applies for complex fabrication (typically $50-200, refundable on production order).
