HPW and Brand KG have set up a joint venture to develop high-performance busbars for EVs, writes Nick Flaherty.

HPW Metallwerk in Linz, Austria, develops high-performance wires for e-mobility while Brand KG in Anröchte, Germany, is a specialist in springs, spring assemblies and wire forming parts.

The aim of the joint venture, called High Performance Busbars, is to bring together key stages of the busbar value chain, from the production of insulated flat wires based on highly conductive copper or aluminium materials, through fully automated forming technologies, to the assembly of complex 3D-bent busbars and complete busbar systems. The joint venture will offer integrated development and production of busbars across Europe, Asia and North America.

Busbars, also known as flat conductors or power rails, are electrical conductors used for the transmission and distribution of energy in electrical systems. In the electrical architectures of modern EVs, they connect the battery, power electronics and drive unit.

Busbars are increasingly replacing conventional cable solutions in the DC charging path of EVs because they reduce weight and installation space owing to their flat design, and they enable improved passive cooling thanks to a larger surface area. The precise and reproducible geometries of the busbars simplify the assembly process in series production and offer cost advantages, particularly when aluminium is used as the conductor material.

As electrification in the automotive sector continues to accelerate, demand for busbars is growing rapidly.

“We have found a perfect partner in the brandgroup and together we will manufacture innovative busbars for the automotive industry through our joint venture. With High Performance Busbars, we gain the opportunity to expand into new and attractive markets. At the same time, the joint venture has direct access to our manufacturing technologies for high-end wires. We are excited about the wide range of opportunities that High Performance Busbars offers for reaching new customer segments,” said Harald Lackner, CSO of HPW.

Daniel Kleineheilmann, general manager r&d of Brand KG said: “As a globally positioned company and technology expert in forming, contacting and assembling busbars, Brand KG complements HPW’s extensive material and manufacturing expertise perfectly. This creates a true win–win situation for both companies, delivering significant added value for our customers.”

With state-of-the-art manufacturing technologies, an international production network and the combined expertise of the two companies, High Performance Busbars aims to be a strategic partner for OEMs and Tier-1 suppliers worldwide. The goal is to provide high-performance, efficient and sustainable solutions for electrical power distribution in vehicles – from early development support to global series production.

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