Abstract: This article presents a comprehensive analysis of busbar design for high-voltage applications, focusing on the current carrying capacity and thermal performance. Busbars simplify high-current distribution, reduce clutter, and can improve reliability if sized correctly. Plan for continuous current + surge; hotspots often occur at studs and. An electric busbar (also written as bus bar) is a metallic bar, strip, tube, or rod that conducts current from one place to another in a safe manner with minimal energy losses. Normally made from copper or aluminium. OEMs first started using busbars in EV batter packs as interconnects for battery modules. They also make sense wherever high power is required, such as connections to. That is where busbars play an important role (Figure 2). These conceptually simple components are easy to describe: a substantial, rigid piece of metal, usually rectangular in cross section and usually made from copper but sometimes aluminum, is used to carry a large amount of current from source.