Because of their advantages over standard electric wire and cable, laminated busbars and flat wire are now used extensively in modern power distribution systems in applications such as electric vehicles, solar and wind energy systems, data centers, and industrial machinery. However, a major challenge in using these conductors in mass production is the need for a fast, clean and accurate process to remove sections of the insulation to ensure a clean and precise electrical connection with electrical components. In this article, we look at how Luxinar, a leading UK manufacturer of sealed CO₂ lasers, is addressing these challenges and helping companies across multiple sectors to modernize their manufacturing processes and stay ahead of the curve in an increasingly competitive market.

For automotive applications, particularly in electric vehicles (EVs) and hybrid systems busbars need to be lightweight and flexible with a current capacity from 100 – 800 A, depending on the design of the battery system and output of the motor. In EV production, busbar material is often supplied in long lengths on a spool, just like a traditional wire. The car maker cuts off the required lengths and bends them to the necessary shapes so they can be routed around a variety of other parts and structures within the car to get the power to where it’s needed.

While most industrial busbars are unlaminated, the busbars used in electric vehicles, solar and wind energy systems, data centers, and some types of industrial machinery are typically covered with insulation to prevent accidental contact, ensure safety, and improve performance by minimizing the risk of short circuits or electrical interference.

However, at the connection points where busbars meet electrical components like transformers, circuit breakers, or distribution boards, it’s necessary to remove sections of this insulation to expose the conductive material and ensure a clean and precise electrical connection.

In recent years, Luxinar has made significant strides in busbar stripping by laser ablation using CO₂ lasers that are optimized to improve precision, efficiency, and reliability in de-coating processes. Learn more in the early view article, to appear in the PhotonicsViews special digital issue on lasers in the e-vehicle production including proceedings articles of the LaserEMobility workshop, out April 2025:

Read the interactive issue in the Adobe Cloud, or download the PDF – Louise May (Luxinar): Solutions for wire and busbar stripping, PhotonicsViews, to be included in the Digital Special Issue D1, April 2025

Contribute to the Special Issue D1 “LaserEMobility”: mailto:photonicsviews@wiley.com