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    Insights

    High Voltage Aluminium Busbars

    As electrification accelerates across automotive and industrial applications, the demand for reliable, lightweight and more sustainable high-voltage solutions is higher than ever.

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    Hydro’s High Voltage Aluminium Busbars are engineered to deliver efficient power distribution, excellent thermal performance and reduced system weight – without compromising on safety or reliability.

    Designed for high-voltage environments, our aluminium busbars support compact system design and high current loads, making them ideal for electric and hybrid vehicles as well as energy and industrial applications.

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    Engineered for performance

    Aluminium Busbars from Hydro Precision Tubing are precision-engineered conductors developed to meet the increasing performance requirements of modern electrified systems. While aluminium requires a larger cross section than copper, the design enables effective heat dissipation, high current-carrying capacity and optimized system efficiency when properly dimensioned.

    By leveraging Hydro’s deep metallurgical expertise and advanced simulation capabilities, we optimize alloy selection, geometry and surface treatments to achieve the best balance between conductivity, thermal behavior, mechanical strength and durability.

    Flexible design and customization

    Our aluminium busbars can be produced in simple or complex geometries, adapted to tight installation spaces and specific customer requirements. You can also have our busbars delivered on coil or fixed lengths, with or without coating. We offer a high degree of customization, including:

    • Flat, round or tailored cross-sections
    • Coated or insulated solutions (e.g. polyamide or polyethylene)
    • Bending, welding and assembly
    • Cut-to-length or integrated solutions

    This flexibility enables seamless integration into compact, high-voltage architectures and supports efficient assembly processes.

    Key benefits

    • Significant weight reduction compared to copper
    • Optimized thermal performance
    • Design freedom through precise extrusion
    • Cost-efficient total system solutions
    • Automotive-grade quality and reliability

    Applications

    • Battery module and battery pack connections
    •  Power distribution units (PDU)
    • Battery junction boxes
    • High-voltage connections in electric and hybrid vehicles
    • Energy storage systems and industrial electrification

     

    Sustainability

    Hydro offers aluminium with significantly lower carbon footprint. Produced using renewable energy, we offer our brand Low-Carbon Aluminium, which carries a significantly lower carbon footprint than the global average. This enables us to help our customers lower their carbon footprint and to prioritize more sustainable solutions.

    Aluminium is infinitely recyclable without loss of qualities, and recycling requires only around 5% of the energy used for primary aluminium production.

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