Ever Wonder How Your Bus Bars Are Made?

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Published On: November 19, 2025
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Before Production

Bus Bars are one of Watteredge’s most common products that we produce for you our customer. If you’re curious about how bus bars are manufactured, this article is perfect for you! Before Watteredge even receives the copper or aluminum meant for your order it is has the chance to be plated with a specific material such as silver, tin, gold, or nickel. The bus bars width and thickness are already cut to the specific measurement you wanted. These bars are typically around 12 feet in length before possibly being cut into smaller peices. Once receiving your order’s materials we transport them into our production area to prepare them to be manufactured.

During Production

A rectangular tin-plated copper bus bar with evenly spaced holes lies on a perforated black metal surface. A gloved hand is visible in motion near the top, and additional metal components and wooden pallets are in the background.
Tin Plated Copper Bus Bar after coming out of Watteredge’s punching machine.

Once being placed on our punching machine your bus bars go through the machine and are punched to your specified design. The bus bars are checked throughout this machining process to ensure your design is being produced correctly. If we are producing multiple parts for you there is a good chance that these parts could be all be produced at the same time in our punching machine. After being punched your parts go down a conveyor belt and are deburred before anything else happens to them.

After bus bars are machined and deburred a couple of other changes can happen. If you have requested it, your bus bars can be bent in various ways. If this is occurring one of our employees will take your bus bars through one of our several bending machines to be bent to your specifications. Furthermore, if you have requested for bus bars to be assembled after machining and bending this will take place too.

 

A Watteredge employee uses a digital caliper to measure a punched bus bar on a workbench, ensuring accuracy before production continues.
A Watteredge employee checks the measurements of the first bus bar of a batch before the Watteredge’s punching machine continues the batch.

Preparation for Shipping

After being bent and assembled bus bars are prepared to be shipped. They are put onto pallets and secured so they are not damaged during transport. After that they are picked up by a delivery truck and are headed your way!

Multiple assembled bus bars are securely packed in a wooden crate and staged in a parking lot, ready for shipment to a customer.
Assembled Bus Bars ready to be loaded and transported to a customer.

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About the Author: Ben Gontarz

Benjamin Gontarz has worked at Watteredge for almost 25 years now. While working for Watteredge he has worked closely with the engineering department and now supervises the Watteredge facilities as the general manager. He has a comprehensive background with the products Watteredge creates. Furthermore, he is one of the longest tenured employees at Watteredge.

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