Copper Busbars

A customer in the power storage industry consulted SMPI when they needed a package of thin-gage copper busbars produced on a very tight production kickoff schedule. We used our in-house fiber laser technology to cut prototypes in just a few hours. Due to higher volumes required, we determined that progressive stamping was the best choice once we exceeded a volume of 5,000. We then produced pre-production parts using laser cutting until our progressive stamping tooling was completed.

After a Level 3 PPAP was approved, SMPI was supplying the customer with production stampings several weeks later. During the tooling build, the customer’s engineering team was able to build testing units at the same time using the laser-cut parts. In the past, C02 laser technology could not cut this highly reflective material, but our fiber laser cuts the copper very quickly and accurately.

Project Details

1. Product Description
   Copper Busbar
2. Capabilities Applied/Processes
Primary:
Fiber Laser cutting
Secondary:
Production Stamping
3. Equipment Used to Manufacture Part
5,000-Watt fiber laser
4. Overall Part Dimensions
.032 x 4.00 x 6.00”
5. Tightest Tolerances
±.005"
6. Material Used
C110 —H02
7. Max Material Finish

8. In Process Testing/Inspection Performed
   Virtek Laser Scanning
9. Estimated Part Weight
10.Industry for Use
Power Storage Industry
11.数量
120,000 EAU
12.Delivery Location
  Midwest, USA
13.Standards Met
Customer supplied print, 2D CAD Drawing,
MIL specifications
ASME Y14.5M-1994
MIL-C-5541
14.Product Name
  Copper Busbar