EV & Battery Storage
6101-T6 alloy offers optimal conductivity and low weight to maximize vehicle range.
- Battery module interconnects
- Inverter & motor connections
- ESS (Energy Storage Systems)
Direct Aluminum Busbar Manufacturer
Aluminum Busbar
Manufacturing aluminum busbars since 2004, Worthwill is a source factory providing precision solutions that optimize performance, cost, and weight.
3-20
Thickness(mm)
Customizable
20-200
Width(mm)
Adjustable
2, 3, 6+
Length(m)
Custom Cuts
Trusted by Industry Leaders SIEMENS ABB BUSWAYS SCHNEIDER
Why Aluminum Busbars Stand Out
Premium 6061, 6101, 6063, 1060, 1070, and 1350 conductors are 70% lighter. Reliable and cost-effective for energy, EV, and industrial use.
See Our Process
How are EC grade aluminum busbars manufactured?
70%
Lighter Than Copper
A 100-amp aluminum bar can be carried by one person. Faster installation, less structural support needed.
60%
Cost Savings
Massive material cost reduction plus logistical savings. Lower shipping costs and scrap rates.
235
W/m·K Thermal Conductivity
Excellent heat dissipation. Lower operating temperatures, ideal for heat sink applications.
Alloy Selection Guide
Choose the right aluminum alloy for your application requirements
6061
High Strength
The "Workhorse" alloy. Excellent corrosion resistance. Perfect for outdoor use.
Conductivity ~40% IACS
Usage HV Switchgear
6063
Universal
Superior finish. Easily extruded into custom profiles; ideal for powder coating.
Conductivity ~58% IACS
Usage LV Panels
6101
EV Optimized
Superior creep resistance over 1350. Ensures long-term stability with minimal degradation.
Conductivity ~56% IACS
Usage EV Battery
1350/1060
Max Conductivity
≥99.5% pure aluminum – lowest resistance when strength isn't the priority.
Conductivity ~61% IACS
Usage Electronics
Industry Applications
Aluminum busbars power critical infrastructure across diverse sectors
Renewable Energy
Cost-effective and efficient power distribution for large-scale renewable systems.
- Solar panel junction boxes
- Inverter DC connections
- Wind turbine control cabinets
Data Centers
Lightweight busways simplify overhead installation for server power distribution.
- PDU (Power Distribution Units)
- Busway trunk systems
- UPS connections
Switchgear
MV/LV Panels
Transformers
LV Connections
Railways
Traction Systems
Marine
Ship Power
Specialty Product
Copper-Clad Aluminum (CCA)
CCA leverages the skin effect to concentrate current in the high-conductivity copper outer layer. It offers a copper-to-copper connection interface with the weight savings of an aluminum core.
10% - 35%
Cladding Ratio
1000 Series
Core Material
Ideal Applications:
- ✓ Retrofit projects replacing pure copper
- ✓ Scenarios requiring copper contact interface
- ✓ Hybrid systems
Hybrid Solution
Best of both metals
Custom Manufacturing
Precision processes for your exact specifications
01
Cutting & Sizing
Standard lengths 2-6m (up to 12m). Laser precision cutting.
Tolerance ±0.1mm
02
Forming & Bending
CNC bending for repeatability. U/L/T profiles.
Radius 1.5-3x thickness
03
Joining
TIG welding (argon), friction stir welding, brazing, crimping.
Multiple methods available
Laminated Busbars
Low inductance, multi-layer insulated design for high-frequency applications.
Accessories Series
Insulators, covers, expansion joints, and mounting hardware.
Aluminum vs. Copper: The Comparison
Make an informed decision for your project
| Parameter | Aluminum | Copper | Winner |
|---|---|---|---|
| Cost | 1.0x (Baseline) | 2.5x - 3.0x | Al |
| Weight (Density) | 2.7 g/cm³ | 8.9 g/cm³ | Al |
| Conductivity (Vol) | ~61% IACS | 100% IACS | Cu |
| Thermal Expansion | 23.1 µm/m·K | 16.5 µm/m·K | Cu |
| Corrosion Resistance | Excellent (with oxide layer) | Good (patina forms) | Al |
When to Choose Aluminum
- → Weight restrictions apply
- → Budget constraints
- → Large-scale outdoor projects
- → Long busbar runs (cost efficiency)
When to Choose Copper
- → Extremely tight spaces
- → Maximum conductivity required
- → Corrosive environments (without plating)
- → High-frequency applications
Core Technical Parameters
Comprehensive specifications for engineering applications
Electrical
Conductivity 40-61% IACS
Resistivity 2.6-4.6 μΩ·cm
Voltage Up to 1000V+
Mechanical
Tensile Strength 130-310 MPa
Yield Strength 80-276 MPa
Hardness 30-95 Brinell
Thermal
Conductivity ~235 W/m·K
Melting Point 658°C
Max Operating 90°C Continuous
Sizing & Ampacity Reference (6101-T61)
6101-T61 offers the best balance of conductivity (~57-59% IACS) and mechanical strength
| Bar Size (mm) | Section (mm²) | Weight (kg/m) | Est. Ampacity (AC) |
|---|---|---|---|
| 25 x 3 | 75 | 0.20 | ~185 A |
| 40 x 6.3 | 252 | 0.68 | ~420 A |
| 60 x 10 | 600 | 1.62 | ~840 A |
| 100 x 10 | 1000 | 2.70 | ~1250 A |
| 120 x 12.5 | 1500 | 4.05 | ~1680 A |
*Data based on 6101-T61 Alloy (57% IACS) at 30°C ambient temperature rise. Actual ampacity depends on orientation and ventilation.
Surface Treatment Options
Enhance performance and durability with specialized coatings
Tin Plated
Standard. Prevents oxidation.
0.05-0.1mm
Silver Plated
Premium. Lowest resistance.
0.01-0.03mm
Nickel Plated
Anti-corrosion. Marine use.
0.05-0.15mm
Powder Coat
Insulation & Color coding.
50-100μm
Anodized
Hard surface. Weathering.
5-20μm
Quality Control
Meeting the quality needs of all customers.
Watch Our Testing Lab
Tensile, Conductivity & Hardness Tests
Incoming
Spectral analysis for alloy verification
Process
Ultrasonic & bend testing
Final
100% visual & salt spray test
Documentation
Full material test reports
ISO 9001 ISO 14001 RoHS UL Listed
Fully compliant with global industry standards including IEC 61439, ASTM B236, DIN 46433, and GB/T 5585.
Packaging & Logistics
Safe delivery to 74+ countries worldwide
Export Standard Crates
Fumigated wooden cases compliant with ISPM 15. Reinforced with steel straps for ocean freight.
Moisture Protection
Each bundle wrapped in plastic with desiccant packs to prevent water stain/oxidation during transit.
Global Delivery
CIF/DDP terms available to 74 countries. We handle customs documentation for hassle-free import.
Lead Time
Standard orders: 15-20 days. Express production available for urgent projects.
Frequently Asked Questions
Common questions about aluminum busbars
Get Your Custom Quote
Factory-direct pricing on precision aluminum busbars. Custom alloys, sizes, and surface treatments. Global shipping to 74+ countries.
✓ Custom alloys & sizes
✓ Surface treatments included
✓ Free samples available
✓ MOQ: 200kg
Response within 24 hours • Engineering support available
