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Creating flexible Busbars is a process that we have perfected over our years of experience within the Metals and Manufacturing industry. Precision measurement, design and equipment that utilises EHRT technology allows us to manufacture the highest quality flexible Busbars for clients in a wide range of industries.

Flexible busbars are created by combining many thin layers of copper or aluminium. A standard unit would consist of copper foils tightly diffusion welded at the mounting areas, which allows each end to remain rigid for other connections whilst keeping the middle flexible. They are designed to distribute power efficiently across AC or DC systems.

As Busbars are the spine of most power applications, providing the all-important interface that the power module needs to connect to the world outside, they must be adequately firm enough to support their own weight. Any external forces such as mechanical vibration and potential environmental factors, which will be considered at the design stage of any system, can have long term effects on the efficiency level of this power infrastructure. Dependent on the country in which this product is used, earthquakes, for instance, could be an extreme consideration when fitting an electrical system.

Factors alongside these external forces to consider when producing bus systems is any problems arising from precipitation in external configurations and outdoor applications. Thermal expansion from drastic temperature changes stimulated by ohmic heating or variations in the ambient temperature, as well as magnetic forces induced by large currents should all be part of the thought process behind manufacture and installation.

Copper flexible busbar manufacturer and supplier in the UK
Aluminium flexible busbar manufacturer and supplier in the UK
Laminated flexible busbars
Wide aluminium flexible busbar
Twisted aluminium flexible busbar

With these environmental factors under consideration, flexible busbars cope admirably with all of these potential problems and provide an elegant solution to a considerable number of inefficiency errors that could arise.

Flexible busbars are used in several different industries because of their durability, robust design for electrical and power applications, and as a sensible alternative to large and small cables and rigid sets. Some examples of their uses would be in Electric, Hybrid and Fuel Cell vehicles, as a power link for generators and within switching cabinets as electrical connectors. They can be used as connections between a main and distribution equipment, between a transformer and a bus-duct, and between a bus-duct and an electrical cabinet, which shows the versatility of application that these products can provide.

We can design and manufacture complete products ready to fit which saves installation time and cuts costs, as well as adhere to any specific performance criteria you may have.

High Quality Flexible Busbar Manufacturer in the UK

ILF Ltd is one of the largest copper specialist within the UK. We are able to build precision metal components for any need using our cutting-edge technology. Our product range includes insulated flexible braided busbar, laminated and flexible connectors. We may also make your product out of steel, brass, bronze, or aluminium on request. We can quickly ship your finished product anywhere in the UK as we are located in the country’s geographic centre.

Why use Flexible Busbars?

A PVC jacket protects the pure electrolytic copper laminates that make up flexible busbar.
The flexible busbar may be easily curved, twisted, and bent to match a variety of panel layouts thanks to how easily the individual laminates slide against one another. Flexible busbar has advantages over normal round cable in terms of saving space because it can replace several round conductors with a single piece of flexible busbar and has a smaller bend radius.
Ring terminals can be removed and fewer conductors can be modified to significantly reduce costs.

Benefits of Flexible Busbars:

  • Less area is needed for wire bending than for regular cable.
  • Greater capacities allow a single flexible busbar to replace many wire configurations.
  • Flexible busbar can be mounted in confined spaces where stiff busbar could not be because of the protective PVC jacket.
  • Decreases the time and expense of installation by doing away with the requirement for lugs.
  • Can replace rigid busbar designs, saving the time required for  engineering and fabrication.
  • Installation is quicker since they are easier to bend and shape than bulky cables.
  • Flexible busbar connections use more surface area, which results in lower operating temperatures at the connection locations.
  • Ring terminals are no longer necessary. To attach the flexible busbar to a rigid bus or electrical conduit, just punch or drill through the exposed end.

Flexible busbar applications include Busbar Systems, Motor Control Centers, Drive Systems, Switchboards, Transformers, Panelboards, Control Panels, Power Supplies, Electrical Machinery, UPS Systems, Low Voltage Power Distribution and Control Applications.


Samples can be produced on request
Flexible Busbars
Best Busbar Supplier in the UK

Available Versions

BF240Length is not availableXXXXXXXXXXXXX
Example: Type + length in mm = type NO.: (X²⁾)= FB100544 (X³⁾)= FB243928

Rated Current at 30°C [IN]

BF25BF50BF1002 x BF100BF240
2 x BF240
2 x BF243
190 A285 A420 A645 A690 A1040 A

An invaluable link in your supply chain delivering quality products on time, every time


Offering quality and precision as standard in busbar and metal component supply