Copper Busbars

A customer in the power storage industry consulted WMPI when they needed a package of thin-gage copper busbars produced on a very tight production kickoff schedule. We used our in-house fiber laser technology to cut prototypes in just a few hours. Due to higher volumes required, we determined that progressive stamping was the best choice once we exceeded a volume of 5,000. We then produced pre-production parts using laser cutting until our progressive stamping tooling was completed.

After a Level 3 PPAP was approved, WMPI was supplying the customer with production stampings several weeks later. During the tooling build, the customer’s engineering team was able to build testing units at the same time using the laser-cut parts. In the past, C02 laser technology could not cut this highly reflective material, but our fiber laser cuts the copper very quickly and accurately.

Copper busbars
dashes

To learn more about this project, including tolerances and inspection processes, please contact us today or see the table below.

Project Details

Product Description Copper Busbar
Capabilities Applied/Processes

Primary:
Fiber Laser cutting

Secondary:
Production Stamping

Equipment Used to Manufacture Part

5,000-Watt fiber laser

Overall Part Dimensions

.032 x 4.00 x 6.00”

Tightest Tolerances
±.005"
Material Used C110 —H02
Max Material Finish

 

In Process Testing/Inspection Performed Virtek Laser Scanning
Estimated Part Weight  
Industry for Use Power Storage Industry
Volume 120,000 EAU
Delivery Location Midwest, USA
Standards Met

Customer supplied print, 2D CAD Drawing,
MIL specifications
ASME Y14.5M-1994
MIL-C-5541

Product Name Copper Busbar