Custom Copper Connectors and Bus Bar

By consolidating all aspects of copper connector and bus bar manufacturing, Storm cuts lead time and outsourcing costs.

As one of the largest global producers of copper bus bar, Storm Power Components offers unmatched dedication to the fabrication of high quality components with the added ability to offer CNC fabrication, testing, electroplating and more.


Storm's In-house electroplating streamlines busbar production, eliminating the time and cost of outsourcing.

Storm offers in-house copper bus bar electroplating of bright and matte tin, lead, tin/lead alloys, nickel and silver. This capability is proven to reduce lead times critical to OEMs.

Not only is internal electroplating is more cost effective than outsourcing, plating in house offers a green component to manufacturing by eliminating fuel consumption and pollution from transport from plant to plant.

Storm's In-house testing equipment also eliminates transport costs.

Quality inspection and testing throughout the bus bar production process to ensures all specifications are met, once more eliminating fuel consumption and pollution from transport from plant to lab.

Storm's full CNC Capability saves even more time.

Virtually all of Storm business involves copper and a variety of core metalworking capabilities, all based on CNC technology. Storm's equipment includes shear, presses, press breaks, water jet and punching machines, to produce materials, processes, and finished components engineered to meet standards required by ISO 9001, ASTM, UL, CSA, Bellcore, and other testing/standards bodies. Storm's prototyping capability can put samples of busbar connectors in your hands for evaluation in a matter of days.

Plus Storm's Engineering Design & Support staff will streamline the custom fabrication of copper busbar.


Copper to Aluminum Ampacity Comparison Chart

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This table is intended to be used as a guideline to help engineers make the proper choice in choosing the correct busbar material for their project.  Your actual design may require more or less of your chosen material based on the specific environmental requirements of your design.  Extensive thermal testing should be done to validate your busbar material choice.

Copper to Aluminum Ampacity/Dimensional Comparison Table

Effect of Dimensions

Tests show that for practical purposes, copper bus bar sizes can be converted to aluminum sizes for equal temperature rise by either of the following two methods:

l. Increase the width of the aluminum bar 27 percent. For example, a 5" x 1/4 aluminum bar is equivalent to a 4" x1/4"copperbar.

2. Increase the thickness of the aluminum bar about 50 percent. A 4" x 3/8" aluminum bar is equivalent to a 4" x 1/4" copper bar.

Increasing the cross-sectional area by increasing the width not only reduces the resistance heating but also substantially increases the area for heat dissipation. A change in thickness of a rectangular bar does not appreciably affect the amount of exposed surface area. For example, increasing the area of 1/4 in. bar by changing the width from 4 in. to 8 in. increases the capacity by about 87 percent, but increasing the thickness of a 4-in. bar from 1/4 in. to1/2 in. increases the capacity by only about 45 percent.  Both examples double the cross sectional area of the bus however there is a 42% difference in the ampacity of the two examples.

Skin Effect Note

* The referenced skin effect ratio reflect the "Thermal Skin Effect" of a conductor and should not be confused with "Electromagnetic Skin Effect".  Thermal skin effect is when, during high current draw, the outside of the conductor remains cool while the inner heats up. This is a result of the outer portion of the conductor managing to radiate some of the heat generated by the current flow while the inner portion of the conductor has to pass any heat to the outer to then be radiated. The electrical result is the innermost portion of the core has a higher resistance than the outer, and as the resistance is higher there is a greater voltage drop meaning more heat is generated resulting in a scenario that could result in a run away state.  This ratio was used to calculate the current ratings of the calculated ampacities listed in this table.