Design Considerations

A Busbar may be the right solution for your power interconnect needs. Consider the following guidelines to determine if a custom busbar might be the best solution for your application.

If any of the following are “True”:

  • Current requirements result in a power cable of 2 AWG or heavier
    • Larger cross sectional areas can be accommodated.
  • Number of terminations becomes too difficult or too expensive to perform
    • Mounting and electrical terminals are an integral part of the busbar and can be labeled in a variety of ways
  • There is a need to reduce assembly costs of complex systems or cabinets
    • Faster assembly and easier repair resulting in lower manufacturing and field costs
  • EMI/RFI is anticipated to be a problem
    • Power busbar can be placed onto the pcb removing traces and layers from the board
    • Power busbar can be accomplished in layers with ground layers between
  • Power distribution wiring must fit into a very tight space
    • Significantly less space (as much as 50% less) is required for busbars vs wire harnesses
  • Power distribution system must be as lightweight as possible
    • Aluminum can be considered where weight is a significant problem

Given a set of electrical, mechanical and environmental busbar requirements, the focus of the design process is to find the optimum combination of materials, configurations and manufacturing processes that will yield a finished product that meets the requirements of the application.


  • Identification of the voltage and current that the busbar will be required to deliver
  • Voltage drop over entire length


  • Materials
  • Plating
  • Cross sectional area
  • Thickness and width


  • Construction
  • Shape
  • Termination methods
  • Mounting methods


  • Temperature extremes
  • Humidity
  • Vibration