Ground Bar Manufacturer - Custom Machined Brass, Copper, and Aluminum Bus bar USA, Europe, and Asia
We do not assume hole positions. We manufacture ground bars that actually work inside a real control panel. We make top quality neutral bar to use in various electrical systems. Whenever you are setting up a power distribution network, control panel, and switchgear to need a ground bar.
Last year, our customer from USA, flagged a Aluminum neutral bar with 2 holes off center by 0.3 mm. We caught an error in pre-ship QC. Re-cut the batch on same night, and shipped it out without delay.
At our factory, we machine custom ground bars with accurate, spec-matching, precise tolerance and real-world durability. Every bar gets fixture aligned before the final cut. With every batch, it gets torque checked.
You want a bus bar that will fit the first time, no bending, no burr, no call-backs. That is exactly what we built.
Types of Neutral Bars - Material-Wise Breakdown
Not all metal bars handle current the same. Depending on the environment, current, and panel design, we machine different types. Each with pros and cons.
Brass Neutral Bars
- Material: C360, CZ121
- Use Case: Domestic panels, small-scale industrial cabinets
- Conductivity: Good (but lower than copper)
- Machinability: Excellent, clean threads, fast cycles
- Corrosion Resistance: Moderate
- Cost: Lower than copper
We ship these across India, UAE, and Southeast Asia for residential and building wiring boxes.
Copper Neutral Bars
- Material: C101 (OFHC) copper
- Use Case: High-load switchgear, solar boxes, rail panels
- Conductivity: Excellent (best choice for current flow)
- Machinability: Fair and clean with sharp tooling
- Corrosion Resistance: High (tin/nickel plating improves it further)
- Cost: Higher
Popular in USA and Europe for solar, EV, and critical electrical panels.
Aluminum Neutral Bars
- Material: 6061, 6082, 6063-T6, 7071
- Use Case: Weight-sensitive panels, transport and modular racks
- Conductivity: Moderate (less than copper, more than brass)
- Machinability: Good and long chip control needed
- Corrosion Resistance: Low (requires surface coating)
- Cost: Lower
Used mostly in bus bar trunking systems, and rail or EV battery housing.
We manufacture as per client’s requirements. We can suggest which material will fit based on your current and enclosure type.
Comparison Table – Brass vs Copper vs Aluminum Neutral Bars
| Feature | Brass Neutral Bar | Copper Neutral Bar | Aluminum Neutral Bar |
|---|---|---|---|
| Material Grades | C360, CZ121 | C101 (OFHC) | 6061, 6082 |
| Conductivity | Moderate | Excellent | Fair |
| Machinability | Excellent | Moderate | Good |
| Corrosion Resistance | Moderate | High (with plating) | Low (needs coating) |
| Common Use Cases | Domestic, OEM Panels | Solar, EV, Switchgear | Rail, Modular Cabinets |
| Finish Options | Natural, Tin, Nickel | Tin, Nickel, Raw | Tin, Anodized, Painted |
| Thread Quality | Very High | High | Good |
| Cost | $$ | $$$ | $ |
Ground Bar Types We Machine
We are not limited to one shape or drill style. We are an OEM custom neutral bar manufacturer. Whether you send a step file, a drawing PDF, or one old sample. We make the type that is needed.
- Two-hole grounding bars
- Neutral bar with lug
- Multi point ground bus bars
- Neutral bars with insulated base
- Tapped bars with captive screw holes
- Chassis-mount and DIN rail compatible
Tolerances We Hold on Ground Bars
We do not leave tolerances up to chance. These are hard specification for us and we hold in production:
- Hole Diameter: ±0.05 mm
- Hole Pitch Spacing: ±0.10 mm
- Bar Flatness: ≤ 0.15 mm per 300 mm length
- Hole to Edge Distance: ±0.10 mm
- Tapped Thread Pitch Class: Metric 6H or UNC 2B (as per requested)
During final QC, we use Go/No-Go gauges, torque drivers, and flat plate checks. If plating is involved then we have to thread undersize and relief chamfer is pre-compensated.
Finishes Available on Ground Bars
Surface is upon your applications. Some bars need raw finish, others need coating.
We offer:
- Natural brass (degreased and deburred)
- Tin plating (for high-current and corrosion-sensitive setups)
- Nickel plating (marine and telecom rack use)
- Electro polished for copper
- Matte bead-blast finish
- Clear anti-tarnish spray (upon request)
All finishing needs post-work include edge deburring and hole cleaning. For example, plated bars, thread tolerances are pre-adjusted before coating.
How We Check Quality
We run on tight tolerance, real people, real quality checks.
- Visual Hole Layout Check: holes matched against drawing
- Thread Gauge Test: every pole point passes Go/No-Go
- Plating Check: thickness verified if specified
- Flatness Jig Test: bar clamped to verify no warp
- Deburr & Clean Pass: final edge check before pack
- Packaging: anti-oxidation wrap, batch tag, drawing copy included
One OEM shipment in Germany failed flatness by 0.4 mm on early sample testing. We re-levelled the fixture bed, ran dummy tests, and the final lot stayed flat within 0.12 mm. That job still repeats today.
Application Industries
We ship custom ground bars across USA, UK, Europe, and Asia to real manufacturing environments. No marketing fluff. Just bars that pass fit tests in actual control panels.
- Power Distribution Cabinets
- Electrical Control Panel
- Telecom Racks
- Solar Combiner Boxes
- Switchgear
- Battery Packs & Inverter Panels
- Rail Control Systems
- Marine Panels & Offshore Installations
Our bars go into both OEM assembly lines and field-installed retrofit boxes.
Recent Job Examples from Our Factory
USA – South Bend, Indiana
Manufacture 30000 aluminum neutral bar quarterly, all holes tapped 8mm, 1.95mm spacing, 122mm length tolerance.
USA – Colorado
Supplied 50000 Pieces of neutral bars, CZ121 brass, slotted mount tabs, blind tapped holes with back chamfer.
Saudi Arabia – Telecom Equipment Build
Custom brass ground bars, nickel plated, 5 mm thick, 1 meter length, exact match to legacy 1990s panel specs.
FAQ – Ground Bars
Q1: Can you machine a neutral bar to match our existing panel holes?
Yes. Send the old bar, or just a dimensioned drawing. We reverse measure it and match it hole to hole.
Q2: Do you provide plated and natural versions?
Yes. Most bars are raw brass and copper. Tin and nickel plating available, with finish cert if needed.
Q3: What is your standard hole tolerance?
±0.10 mm. For tighter specs, we can hold ±0.05 mm on shorter bars if fixture allows.
Q4: Can I get thread + Fixer holes in the same bar?
Absolutely. Mixed-hole bars are common. We mark each clearly in drawings and in QC.
Q5: How fast can you ship to the USA?
Samples: 5 to 7 working days. Production: 10 to 15 days typical. Express courier, with tracking and customs support.
Q6: Can I send a DXF and Step 3D model?
Yes. DXF, STEP, IGES, and even a drawing all work. We confirm specs before starting.
Q7: Do you supply material certificates?
Yes. Brass, copper, and aluminum. All come with batch traceability and certs on request.
Get a Free Ground Bar Quote – Fast Response
Whether you need 1000 bars for a small batch or 1,0000 mass production for a panel line. We machine what fits.
- Manufacture according to your drawing
- Fast machining, real fit accuracy
- Tin/nickel plating if needed
- Batch repeat accuracy every time
Request a Free Ground Bar Quote Now
