Engine mounts, chassis parts, and machined components for assembly lines.
High-strength fasteners, landing gear parts, and structural assemblies.
Forged housings, armor brackets, and mission-critical structural parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Busbar holders, battery pack parts, and lightweight structural enclosures.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Large welded frames, PEB structures, and assemblies for industrial equipment.
High-performance cables and wires engineered for durability and seamless connectivity across applications.
Custom-built wiring harnesses for secure connections and streamlined installations.
Precision-engineered busbars for efficient power distribution and minimal energy loss.
Robust connectors designed for secure locking, reliable conductivity, and long-term performance.
Durable transformers built for consistent performance, energy efficiency, and stable power regulation.
Frigate’s industrial-grade heat sinks provide efficient, customizable cooling for high-performance thermal management.
Diverse solutions covering automotive, electrical, mechanical, and industrial needs with precision-built components.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Frigate CNC Machining offers high-precision, custom solutions for complex casting geometries. Multi-axis capabilities ensure tight tolerances and optimal surface finishes.
Sheet metal fabrication uses laser cutting, punching, and bending for precision.
Frigate Sheet Metal Fabrication utilizes advanced laser cutting and press brake technology for custom casting applications. Tight tolerances, superior welds, and high-strength materials ensure structural integrity.
Injection molding produces high-precision parts with consistent quality.
Frigate Injection Molding delivers custom-engineered parts with micron-level precision and structural integrity. Specialized molds maintain tight tolerances for complex geometries and high-stress applications.
Precision casting ensures accurate, high-quality parts.
Forging services improve material strength with precise tolerances.
Frigate Casting Services provides custom casting with tight tolerances and complex geometries. We enhance material properties using advanced metallurgy, ensuring strength and wear resistance. Our precision methods support high-performance aerospace, automotive, and industrial applications.
End-to-end part production from samples to bulk supply.
Ready-to-use assemblies built to exact fit and function.
Heavy-duty fabrication with high-strength materials for demanding applications. Robust welding for maximum structural durability.
Copper, Aluminum, or Copper Alloy
10 – 50 microns (depending on application)
2 mm to 10 mm (customizable)
10 mm to 100 mm (customizable)
Copper: 58 MS/m, Aluminum: 35 MS/m
Machined busbars are crafted from high-conductivity materials such as copper or aluminum, ensuring optimal electrical flow with minimal resistance. This high conductivity reduces energy loss, translating into more efficient systems and lower operating costs. You can count on these busbars for commercial, industrial, or high-performance applications to deliver superior power transmission, reducing system inefficiencies and boosting your overall operational performance.
Copper: 390 W/m·K, Aluminum: 205 W/m·K
Up to 1000 V (customizable for higher ratings)
Up to 5000 A (depending on size and design)
-40°C to 150°C (with high-temp options)
High resistance to corrosion in industrial environments
Tensile strength up to 250 MPa (for copper)
99% adhesion under standard testing conditions
Smooth, Polished, or Matte (depending on requirement)
Custom dimensions, hole patterns, and finishes
RoHS, UL, ISO 9001, IEC, and other industry-specific standards
Unlike traditional stamped or extruded busbars, machined ones are manufactured with precision CNC. This allows for tight tolerances, which means the busbars can be custom-designed to fit unique system requirements. Whether integrating these bars into complex panels or custom machinery, you get a solution that fits seamlessly, reducing the need for additional adjustments during installation.
The robust construction of machined busbars ensures long-lasting performance. These bars are engineered to withstand harsh environments, including high temperatures and corrosive conditions, which is crucial for automotive, aerospace, and energy industries. By choosing machined busbars, you’re investing in a solution that minimizes the risk of wear and tear, ultimately extending the life of your power distribution system and reducing costly maintenance and replacements.
Need reliable Bus Bars for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
This system connects battery packs to inverters, motors, and control systems, optimizing energy flow and performance.
Provides reliable power distribution in automation equipment, protecting critical machinery and minimizing downtime.
This system distributes electrical power across servers, cooling units, and backup systems, ensuring constant uptime and performance.
Used in aircraft power distribution systems to manage electrical connections in critical flight and navigation systems.
Facilitates power distribution in cell towers and communication equipment, ensuring minimal signal disruption.
Provides power connections in offshore platforms and refineries, supporting high-load operations in harsh environments.
Integrating busbars that are easy to install and maintain is a huge benefit for complex electrical systems. Machined busbars are designed for quick, efficient assembly with reduced need for additional hardware or wiring. This not only saves installation time but also reduces the chance of errors, contributing to a more reliable and cost-effective electrical system overall.
Machined busbars must carry high current loads in many industrial applications without flexing or degrading. Their strength and stability ensure that they maintain their integrity under heavy electrical loads, minimizing the risk of power failures. Their rigid design ensures reliable performance even in high-demand systems.
Check all our Frequently Asked Question
Machined busbars are typically made from high-conductivity metals like copper or aluminum. With its superior conductivity, copper reduces energy losses during power transmission, while aluminum offers a lightweight alternative with good conductivity. The precision machining process ensures smooth surfaces, which minimizes contact resistance and further enhances the efficiency of the electrical flow, reducing power loss and heat generation.
Thermal expansion can cause significant issues in power distribution systems, especially when busbars experience high currents. Machined busbars are designed with materials with a low coefficient of thermal expansion, such as copper or aluminum alloys, ensuring that they maintain their shape and size under thermal stress. This minimizes the risk of mechanical failure, misalignment, or loose connections, enhancing the safety and longevity of your system.
The precision of machined busbars allows for tight manufacturing tolerances. This level of accuracy ensures that the busbars fit perfectly into electrical enclosures, connectors, and mounting systems. Such precision helps reduce the risk of electrical arcing or poor connections, which could otherwise lead to system failure, short circuits, or downtime. With machined busbars, you can trust that every component will perform as expected.
Machined busbars are engineered to handle high short-circuit currents without failure. Their robust design and strong material choices, such as copper or tinned copper, allow them to withstand the intense heat and forces generated during a short circuit. This capability ensures the busbars remain intact, preventing catastrophic system failures and ensuring the power distribution system operates safely under extreme conditions.
The surface finish of machined busbars plays a crucial role in electrical and mechanical performance. A smooth, polished surface minimizes contact resistance, reducing energy loss and heat generation during operation. Additionally, a well-finished surface provides better corrosion resistance, ensuring the busbars last longer in harsh environments. The precision machining process also reduces the chance of surface irregularities, which could lead to mechanical stress points or weak connections.
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818, Preakness lane, Coppell, Texas, USA – 75019
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!