Stamped Busbars
Busbars distribute electricity with greater ease and flexibility than some other more permanent forms of installation and distribution. Also called bus bars or buss bars, they are often metallic strips of copper, brass, or aluminum that both ground and conduct electricity.
China Plate Contact ensures your power distribution system operates dependably and safely with high-quality busbars. We are an industry-leading supplier of stamped metal parts and assemblies for use in a variety of industries, and we specialize in high-performing busbars for demanding environments.
With the surging demand for electric vehicles in recent years, we have enhanced our technical capabilities to manufacture tailored busbars designed for transmitting power in a wide range of electric vehicles.
OPTIMAL BUSBAR PERFORMANCE
Like all electrical circuits, busbars need protection against the effects of short-circuit currents. Any openings increase the risk of debris accumulation in air gaps and the chance of subsequent damage increases due to high normal operating currents and the amount of energy available. China Plate Contact leverages 3D modeling and tooling simulation, sensor and inspection technology, and the finest tooling and metal stamping techniques to produce busbars that fit correctly and perform optimally at a competitive cost. Our full range of services include:
- Progressive die heavy stamping
- Progressive die high-speed stamping
- Tool and die design and manufacturing
- Rapid prototyping
- Assembly services
- Waterjet cutting
Quality Assurance
At China Plate Contact, quality is our utmost priority. We conduct a feasibility review on the part to ensure manufacturability at the start of every program. A run-at-rate study is also implemented on the first run to ensure quality before large-scale production. This enables our quality and production management teams to monitor controls closely and make sure jobs run smoothly. Manufacturing continues once testing checks out, and the first batch of conforming parts is produced.
Our quality management system is comprised of sophisticated quality technology and controls, continuous improvement programs and a superior quality laboratory and management team. Throughout our production plant, we deploy camera vision systems and sensor technology, in which we design and fabricate unique to every production program. Our vision system technology operates in coordination with our stamping production machinery to thoroughly inspect and identify part features and dimensions with automated camera imaging. This quality control process ensures every part produced with our stamping equipment always yields 100% quality and zero defects.
Power your application more effectively with high-performing busbars from China Plate Contact. With a dedicated team, innovative equipment, and superior quality control, we provide exceptional services tailored to each customer’s unique needs.
Busbar Applications
- Batteries
- EV AC invertor (automotive)
- Battery pack
- Fuse panel
- Circuit breaker
- Charging inlet
- Drive units
- DC-to-DC converters
- AC-to-DC converters
- Heaters
- Air compressors
- Power converters
- Power inverters
- Batter Disconnect Units (BDU)
- Junction Box
- Gate Drivers
- Insulated-gate bipolar transistor (IGBT)
- Power Block
- MOSFET
- Power Distribution Unit (PDU)
- HV Charging Units / Superchargers
- Busway Systems
Metal Stamping Design Features
China Plate Contact offers a range of stamping design features to meet your unique requirement. Stamping design features include:
- Bi-Metal
- Coated
- Coined
- Compliant Pin (eye of the needle)
- Countersunk Holes
- Critical Dimensions
- EB Welded
- Embossed
- Enameled
- Eyelets
- Flat
- Formed
- Heat-Treated
- IDC Slots
- Injection Molded
- Inlay
- Insert Molded
- Multiple Stamping
- Numbering
- Powder Coated
- Precious Metal Plated
- Reeled
- Riveted
- Shape Critical
- Skived
- Stacked
- Strain Relief
- Surface Critical
- Surface Mounted
- Tapped
- Threaded
- Tip Coin
- Tox Lock
- Tuning Forks
- Welded
Post-stamping Operations
To complete finished production parts, we offer final post-production process operations prior to product packaging and delivery. Examples of post-manufacturing operations we provide include:
- Heat Treatment
- Deburring
- Washing/Degreasing
- Post-Plating (pre-plating option also available)
- Surface Coating
- Post-Hardware Installation (in-die hardware assembly can also be performed)
Metal Stamping Materials
Although each metal has its own blend of mechanical, chemical and surface properties, our knowledgeable engineering and production teams have decades of experience and can achieve optimum results from a variety of metals. Our team develops the right tooling techniques to ensure the unique properties of any metal are yielding exactly what our customers require for their metal stampings. Material types we commonly work with include:
- Copper
- Brass
- Phosphor Bronze
- Beryllium Copper
- Steel
- Stainless Steel
- Carbon Steel
- Aluminum
- Galvanized Steel
- Titanium
- Platinum
- Inconel
- Hastelloy
Plating Material Finishes
We offer a range of pre- and post-plating options for metal stamping assemblies to allow for corrosion protection, electrical conduction, decorative use, wear resistance, coloring, bonding, and lubricity. You can choose between overall plating, select plating, or spot plating application. Metal stampings can be reel-to-reel plated, barrel plated, rack plated, vibratory plated, or selective-loose-piece plated. Plating material finishes include:
- Copper
- Nickel
- Tin-Lead
- Tin
- Palladium
- Palladium-Nickel
- Silver
- Gold
- Zinc
Surface Coating Applications
Stampings may require a surface coating for dielectric insulation, application environment protection, heat and extreme temperature protection, abrasion protection and corrosion protection in various electrical applications. Coatings can be applied through a fluidized bed dip process, electrostatic fluidized bed dip process and electrostatic spray process, among other application methods. China Plate Contact produces metal stampings with an assortment of coating applications to meet your needs. Some examples of surface coatings include:
- Epoxy Powder Coating
- Nylon Powder Coating
- PVC Powder Coating
- Polyethylene Powder Coating
- Polyurethane Powder Coating
- Polyester Powder Coating
- Vinyl Powder Coating
- Vinyl Plastisol Liquid Coating
STAMPING ASSEMBLY PROCESSES
China Plate Contact offers complete stamping and product assembly. With all manufacturing processes under one roof, we provide a cost-effective finished product with particular attention to quality, production deadlines, and the feasibility of end-use. Examples of assembly processes we provide include:
- Automated In-Die Assembly
- Automated Robotic Assembly
- Secondary Semi-Automated Assembly
- Threading
- Staking
- Tapping
- Hardware Insertion
- Joining
- Stacking
- Welding
- Riveting
Stamping Assembly Hardware And Part Installations
For assembled applications, parts may require joining of metal hardware, plastic parts or metal inserts. Examples of assembly hardware and part installations are:
- Plastic Pieces
- Metal Inserts
- Fasteners
- Screw Machine Parts
- Pemserts
- Bushings
- Nuts
- Studs
Industries
It’s our mission to offer premier metal stamping and metal forming solutions to the most challenging and innovative engineering product designs. We combine advanced metal stamping production and tooling equipment, superior quality controls, seamless automation and production processes, and a knowledgeable and experienced team to serve an array of market segments.
Services
Since 1941, we’ve continued to expand our service offering by taking on new capabilities with our industries' top-performing technology and equipment. This ensures production runs most efficiently and parts are 100% quality assured. From engineering and design through stamping production, we offer a full suite of metal stamping, metal forming, tooling and assembly services to allow OEM and tier manufacturers the ability to reduce and streamline their supply base. We are fully equipped and highly qualified to meet the special product requirements of multi-million-part stamping production programs.
Other Production Parts
China Plate Contact produces a variety of precision metal stampings made from copper, precious metal and ferrous metals. We produce stamping components such as busbars, brackets, electronic shielding components, lead frames, press-fit pins, terminals, wire and cable connectors, assemblies and more. We specialize in manufacturing of both precision electrical connectors and non-electrical parts that are used in our world’s most demanded consumer products and essentials.
