Engineered Power Distribution Solutions
As a leading custom busbar manufacturer, Dongguan Haocheng Metal Spring Co. Ltd. designs and produces high-conductivity electrical connection systems. We specialize in optimizing electrical performance, thermal efficiency, and mechanical durability for demanding environments.
Our custom busbar configurations are engineered to handle high current loads while minimizing space requirements, making them ideal for modern electric vehicle (EV) battery packs, power conversion modules, and renewable energy storage systems.
- High-purity raw copper (C11000/C10100) and premium aluminum alloys.
- Advanced insulation technologies including epoxy powder coating and heat-shrink sleeving.
- Precise CNC machining and high-speed metal stamping for tight-tolerance specifications.
Why Custom Busbars Matter
Off-the-shelf power connections fail to meet the tight space constraints, vibration resistances, and thermal demands of modern new energy systems. Custom busbars offer:
High-Conductivity Custom Busbar Catalog
Explore our comprehensive range of custom copper and aluminum busbars. Click on the categories below to view detailed specifications or request tailored modifications.
EV High-Power Busbars
Optimized busbar design engineered to handle high-amperage demands of modern EV drivetrains.
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Motor Stator Busbar
Compact and highly insulated busbars designed for electric motor stator connections.
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New Energy Custom Busbars
Tailored power distribution configurations for wind, solar, and smart grid applications.
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Flexible EV/ESS Copper Busbars
Multi-layer soft copper connections built to absorb thermal expansion and vibration.
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Soft Copper Busbars
High-flexibility connections designed for tight installation radii in power distribution cabinets.
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Flexible Copper Connections
Laminated copper foils welded at terminals to provide maximum electrical conductivity and flexibility.
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Conductive Aluminum Busbars
Lightweight aluminum power distribution bars for weight-sensitive applications.
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Grounding Wire Busbars
Distribution box grounding connections designed for high surge-current capacity.
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Cord End Terminals
Non-insulated high-conductivity terminals for heavy-duty wiring and power connections.
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CNC Copper Terminal Blocks
Precision-machined European standard OTD copper terminal blocks for industrial power systems.
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New Energy Soft Copper Connections
High-flexibility connection bars optimized for structural transitions in power grids.
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Conductive Copper Busbars
Standard rigid copper bars with high electrical purity, ideal for switchgears and panels.
View Product Details →Engineering & Custom Fabrication Capabilities
We transition custom designs from initial prototype to mass production using state-of-the-art metal forming and finishing technologies.
Precision CNC Machining
Our advanced tooling handles complex geometries, custom drilling, tapping, and edge milling. We achieve tight tolerances of up to ±0.05mm, ensuring seamless alignment in compact EV battery packs.
Advanced Insulation & Coating
We offer high dielectric strength coatings including electrostatic epoxy powder coating, heat-shrinkable tubing, and PA12 coating, providing up to 1000V insulation for high-voltage EV architectures.
Surface Plating Options
To optimize electrical conductivity and prevent oxidation, we provide in-house plating services including Bright Tin, Matte Tin, Nickel, Silver, and Gold plating, ensuring long-term corrosion resistance.
Company Profile
Dongguan Haocheng Metal Spring Co. Ltd. was founded in 2005, all kinds of precision metal spring, stamping professional production manufacturers. Company covers an area of over 10,000 square meters, the plant area of over 6,000 square meters, with more than 100 Taiwan modern precision production equipment and testing equipment, such as Taiwan CNC502 computer spring machine, Taiwan CNc8cs computer spring machine, automatic lathes and Taiwan High-speed presses, Taiwan steel punch, automatic tapping machine, high-speed centrifugal grinding machine, pull pressure testing machine, torque testing machine, projector, the second element detector, salt spray test machine, film thickness, hardness, continuous Heattreatment furnace.
Has a group of skilled and experienced production technology and management personnel. The company also continued from Japan, Taiwan and other places the introduction of advanced production and testing equipment to improve efficiency and quality, while continuous production and testing automation research and development and improved greatly shorten the product open-proof and proofing cycle and improve the work. According to customer demand, the company can design and manufacture all kinds of precision springs, stamping parts, car parts, screws, Corn, in order to meet the different customers of all kinds of high-quality, high efficiency, high efficiency, demand.
Our products are widely used in various automotive, electronic products, household appliances, electrical lighting, computers, mobile phones, printers, photocopiers, fax machines, connectors, home appliances control panel, and other fields.
Haocheng Growth
A timeline of continuous innovation, manufacturing expansion, and quality optimization.
2005
Company established, specializing in precision metal stamping and spring manufacturing.
2007
New site movement to expand production floor capacity and accommodate larger machinery.
2009
New site movement to catch the rapid growth in industrial and automotive sectors.
2016
Workshops consolidation (spring & metal stamping parts & machine parts) to streamline operations.
Sales Growth & Market Trust
Our steady financial and market growth is a direct reflection of our dedication to quality, cost-efficiency, and on-time delivery. Over the last decade, Haocheng has scaled its manufacturing capabilities to serve global tier-1 automotive suppliers and leading electrical product brands.
Our financial stability ensures continuous reinvestment in advanced fabrication technologies, computerized testing equipment, and R&D automation, allowing us to keep shortening prototype turnarounds and production lead times.
Sales Growth (Unit in Ten Million RMB)
State-of-the-Art Production Workshops
We operate highly specialized production facilities to maintain absolute control over product quality and manufacturing capacity.
Spring Production Workshop
Equipped with 30 Taiwan precision CNC 502 computer spring machines and CNC8CS Yahuang computer machines. Managed by highly skilled technical staff, we fabricate precision springs ranging from Ø0.08 to 5.0mm. We deliver high-precision mechanical components with consistent performance and reasonable pricing.
Metal Stamping Workshop
Featuring high-speed precision tonnage metal stamping machines, high-precision mold-making equipment, and self-tapping equipment. With 18 years of manufacturing experience, we specialize in high-volume metal stamping parts widely used for home appliance control panels, terminals, inserts, electrical mesons, and busbar terminals. We guarantee superior quality and on-time delivery.
Strict Inspection & Quality Control
To meet the stringent safety standards of high-voltage automotive and power transmission systems, Haocheng implements a zero-defect quality policy. Our testing lab is equipped with advanced diagnostic equipment to ensure structural and electrical integrity.
- Second Element Detector & Projector: Ensures structural precision and dimensional compliance.
- Salt Spray Testing Machine: Verifies corrosion resistance of plated copper and aluminum surfaces.
- Pull Pressure & Torque Testers: Tests mechanical limits of flexible busbar connections and terminals.
- Film Thickness & Hardness Testers: Ensures uniformity and durability of insulation and plating coatings.
Our Culture & Values
Driven by integrity and a commitment to collaborative success.
Our Goal
The Global leading metal products manufacturer.
Our Mission
Value creation for our clients, Win-Win corporation.
Our Value
Honesty, fair, reliable, creative.
Corporate Style
Hardworking, strict, trustworthy.
Technical FAQs: Custom Busbar Manufacturing
Get expert answers to common engineering questions about custom electrical busbars.
High-purity copper (C11000 ETP or C10100 OFC) is typically preferred for its superior electrical conductivity (100% IACS). For applications where weight reduction is critical, such as aerospace or specific EV structural frames, aluminum (typically 6061 or 1050 alloys) is utilized, offering approximately 61% of copper's conductivity at half the weight.
Flexible copper busbars are fabricated by laminating multiple thin sheets of copper foil and bonding the ends through press-welding or soldering. This multi-layered structure allows the center of the busbar to bend and flex, absorbing vibrations, shock, and thermal expansion/contraction within EV battery modules without stressing the connection terminals.
We provide electrostatic epoxy powder coating, which offers excellent dielectric strength, thermal stability, and tight contour wrapping. We also offer flame-retardant PVC/PE heat-shrink tubing and high-durability PA12 (Nylon) coatings to meet safety standards up to 1000V DC.
Yes. Our engineering department uses CNC milling and laser cutting to produce low-volume prototypes quickly. Once the design is validated for electrical and thermal performance, we transition the project to high-speed progressive die stamping for cost-effective, high-volume production.
Ready to Engineer Your Power Connections?
Partner with a proven custom busbar manufacturer. Whether you need rigid copper bars, flexible laminated connectors, or precision CNC-machined terminals, Haocheng Metal delivers high-quality components tailored to your exact specifications.
What happens next?
- Engineering review of your CAD/technical drawings within 24 hours.
- Material selection and surface plating recommendation.
- Competitive quotation and rapid prototyping timeline.
Quick Project Inquiry
Submit your requirements directly to our technical sales team.
