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The Power of Copper Busbars: Unleashing the Benefits of a Time-Tested Solution

In the realm of electrical power distribution, copper has long been regarded as the gold standard for busbars. Renowned for its exceptional conductivity, low resistance, and durability, copper has consistently proven to be a reliable and efficient choice for transmitting electricity.

Copper busbars equate to around 85% of the busbars manufactured by HV Wooding. There are numerous benefits of using copper busbars and this material remains a top contender in power distribution applications.

At HV Wooding we produce copper busbars to specification, down to 0.3mm and are able to offer a highly responsive service, even with tight lead-times, utilizing state-of-the-art EHRT Punching & Forming Machines.

We offer in-house electroplating and powder coating  Our applications range from utilizing polyolefin and PVC for 11KVA switchgear in the energy and rail sectors, to more complex busbars for EV/Hybrid battery systems that are coated with a range of insulation materials, including resicoat HGF03R (red),  HFG03R (orange) and Nylon BB, to achieve ratings between 1.5 and 5KV.

Why are Copper busbars so popular? 

Superior Electrical Conductivity

Copper stands unrivalled when it comes to electrical conductivity among common metals. Its remarkable conductivity, which is approximately 60% higher than that of aluminium, allows for efficient and low-resistance power transmission. Copper busbars enable the flow of electricity with minimal losses, ensuring optimal efficiency and reducing the chances of overheating. This characteristic makes copper the go-to material for applications that demand high current-carrying capacities and superior electrical performance.

Exceptional Thermal Performance

In addition to its outstanding electrical conductivity, copper exhibits excellent thermal conductivity. This attribute allows copper busbars to effectively dissipate heat generated during power transmission, mitigating the risk of overheating and ensuring reliable operation. The ability to efficiently regulate temperature enhances system reliability, reduces the need for additional cooling mechanisms, and extends the lifespan of connected components and equipment.

Robust Mechanical Strength

Copper’s mechanical strength and durability make it an ideal choice for busbars subjected to various mechanical stresses. Its high tensile strength enables copper busbars to withstand mechanical forces, such as vibrations and impacts, without compromising structural integrity. This robustness ensures long-lasting performance and minimizes the risk of damage or failure in demanding environments.

Corrosion Resistance and Longevity

Copper possesses natural corrosion resistance, making it highly reliable in diverse operating conditions. It can withstand moisture, humidity, and many corrosive elements commonly encountered in industrial environments. Copper busbars retain their integrity over extended periods, minimizing the need for frequent maintenance or replacement. This corrosion resistance guarantees uninterrupted power transmission and enhances the overall reliability of the electrical system.

Compatibility and Flexibility

Copper’s compatibility with other materials commonly found in electrical systems is another advantage. Its low contact resistance ensures efficient electrical connections, reducing energy losses at connection points. Copper busbars can easily be connected to various components, including switches, circuit breakers, and transformers, without compromising performance. Furthermore, copper’s malleability allows for easy shaping and bending, enabling the creation of customized busbar configurations to suit specific application requirements.

Sustainability and Recyclability

Copper is a sustainable choice for busbars due to its longevity, recyclability, and minimal environmental impact. Copper busbars have a long operational life, reducing the need for replacements and contributing to resource conservation. Furthermore, copper is fully recyclable, with a high recycling rate globally. The recycling process requires significantly less energy compared to primary copper production, making it an environmentally friendly option and supporting a circular economy.


Copper busbars have been a cornerstone of efficient power distribution for decades, and their benefits continue to shine. With superior electrical conductivity, exceptional thermal performance, mechanical strength, and corrosion resistance, copper remains unmatched in its ability to ensure reliable and efficient power transmission. Its compatibility, flexibility, and sustainability further solidify copper’s position as the material of choice for busbar applications. As industries strive for optimized electrical systems and sustainable solutions, copper busbars stand tall, delivering unparalleled performance and contributing to a greener future.

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