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.
High-grade Aluminum Alloy (e.g., 1050, 6063)
3-15 microns (customizable based on application)
5 mm to 50 mm (customizable)
20 mm to 200 mm (customizable)
55-60% IACS (International Annealed Copper Standard)
Aluminum busbars are significantly lighter than copper, which can reduce shipping costs and ease installation. They provide the same conductivity performance at a fraction of the weight, offering you the flexibility to design compact power distribution systems that minimize the need for heavy infrastructure. The reduced weight translates to easier handling, lower labor costs, and efficient material usage, ensuring your project stays within budget.
150-220 W/m·K (depending on alloy composition)
Up to 36 kV (depending on insulation and application)
100 A to 10,000 A (customizable based on size and design)
-40°C to 105°C (depending on coating and environment)
Excellent resistance to oxidation and corrosion in various environments (marine, industrial, etc.)
Tensile Strength: 150-250 MPa (depending on alloy)
High adhesion strength, ensuring long-term durability
Smooth, anodized, or powder-coated (customizable)
Shape, size, coating type, voltage and current ratings
IEC 60853, UL 486A, RoHS compliant
Aluminum is naturally corrosion-resistant, making aluminum busbars ideal for use in environments exposed to moisture, extreme temperatures, or chemicals. The inherent corrosion resistance prolongs the life of your power distribution systems, reducing maintenance needs and preventing failures caused by rust or degradation over time. This is especially beneficial for industries such as utilities, construction, and outdoor power installations.
Aluminum busbars are designed to efficiently carry high currents. With advancements in alloy technology, modern aluminum busbars can carry more current than ever, making them suitable for high-demand applications. Their robust design ensures that your electrical systems can handle substantial loads without overheating or risk of failure.
Need reliable Bus Bars for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Aluminum busbars enable power transmission in high-voltage substations, enhancing grid stability.
Used in large HVAC control systems for efficient power distribution to compressors, fans, and motors.
Provides power distribution in vehicles and equipment, ensuring durability in extreme conditions.
Battery Energy Storage Systems (BESS) distribute power in energy storage systems to stabilize the grid and integrate renewable energy.
Delivers power within telecom stations, ensuring uninterrupted service in critical communication networks.
Powers onboard electrical systems, from navigation to propulsion, ensuring high reliability in maritime operations.
Aluminum busbars can be fabricated in various shapes and sizes, allowing for space optimization in electrical panel designs. Their compact form factor reduces the need for bulky wiring and supports a more organized, efficient setup. This design flexibility is critical for projects with space constraints or where maximizing available room is essential.
With aluminum busbars, you can significantly reduce the risk of electrical failures due to overloading or poor connection quality. Their design and material properties allow for secure, stable connections that enhance the overall safety of your electrical systems. This is especially important for industries requiring high levels of safety compliance, like aerospace, automotive, and data centers.
Check all our Frequently Asked Question
The alloy composition and heat treatment of aluminum busbars play a key role in their electrical conductivity. By using high-quality aluminum alloys, such as 1050 or 6063, and applying specific heat treatments, the busbars can be optimized for higher conductivity. This ensures minimal power loss, improved efficiency, and reliable performance under high-current conditions. The alloy’s purity and treatment process directly influence the busbar’s ability to transmit power efficiently without excessive heat buildup.
Surface treatments like anodizing and powder coating significantly enhance the corrosion resistance of aluminum busbars. Anodizing increases the thickness of the aluminum oxide layer, providing an effective barrier against moisture, chemicals, and extreme temperatures. This process is crucial for outdoor, marine, or chemically aggressive applications, extending the busbars’ lifespan and reducing maintenance costs.
The mechanical properties, such as tensile strength and hardness, are critical in determining the load-bearing capacity of aluminum busbars. Using high-strength aluminum alloys ensures the busbars withstand mechanical stresses during installation and operation. These properties also contribute to their long-term durability, preventing deformation under heavy electrical loads or mechanical strain and ensuring consistent performance over time.
Aluminum has a higher thermal expansion coefficient compared to other metals like copper. This means that aluminum busbars expand and contract more with temperature changes. Busbars are often designed to mitigate this with proper thermal management features, such as expansion joints or reinforced supports. Understanding and controlling thermal expansion is critical in ensuring the busbars maintain stable connections and prevent electrical failures in environments with significant temperature fluctuations.
While copper is known for its higher conductivity, aluminum busbars offer significant advantages in high-current applications, especially in weight and cost. Aluminum’s lower density makes it much lighter, reducing the mechanical load on support structures and simplifying installation. Additionally, aluminum busbars are generally more cost-effective, making them a more economical choice without compromising on performance, especially when paired with advanced alloys and design optimizations.
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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!