Powering Data Centres with Precision Busbar Production

Modern data centres are built around a highly reliable and scalable power distribution architecture. At the core of this infrastructure are busbars, used to transfer high current between transformers, switchgear, UPS systems and distribution units.

These systems rely on precision-manufactured flat bars in copper and aluminium, forming the backbone of electrical distribution across the facility.

Vaski delivers fully automated flat bar processing solutions designed to meet the accuracy, repeatability and throughput requirements of busbar manufacturers serving the data centre industry.

Where Busbars are used in Data Centres

Busbars are critical components across the entire electrical chain:

  • Main switchgear and low voltage distribution systems
  • UPS systems and battery connections
  • Transformer connections
  • Power distribution units (PDUs)
  • Busbar trunking systems for scalable power distribution

These applications require high-current conductivity, tight tolerances, and reliable mechanical connections, making manufacturing quality a critical factor.

Challenges in Busbar Manufacturing

  • High precision and repeatability, requires:
    • Accurate hole positioning for bolted connections
    • Consistent bending angles for assembly fit
    • Clean edge finishing to ensure insulation safety
  • Increasing production volumes (large batch production, short lead time and need for automation).
  • Material variability – copper, aluminium and steel. Each material requires controlled processing to maintain quality and avoid deformation.
  • Integration into automated production
    • Continuous production lines and activities
    • Reduced manual intervention
    • Digital integration with CAM

Manufacturing requirements from suppliers

  • Flexible punching for multiple hole patterns
  • Multi-step processing: punching, threading, marking, forming
  • Accurate bending for complex geometries
  • Efficient material handling and storage
  • Scalable automation for high-volume production

Flat bar processing must support continuous, programmable production with minimal downtime.

Vaski Solutions for Busbar Manufacturing

Fully Electric Flat Bar Processing

Vaski solutions are built around servo-electric technology, enabling:

– Up to 80 percent lower energy consumption compared to hydraulic systems

– Reduced maintenance and downtime

– High-speed and quiet operation

VaskiPUNCH

Precision Punching for Busbar Production

Designed for punching, cutting, threading and marking flat bars:

  • Automatic servo-electric punching system
  • Multi-tool configurations for flexible hole patterns
  • Capability to process flat bars up to 260 mm width and 20 mm thickness depending on model

Key benefits:

  • High accuracy for electrical connections
  • Reduced setup time with multi-tool systems
  • Suitable for copper, aluminium and steel

VaskiBEND

Accurate Bending for Complex Busbar Geometry

Servo-electric bending solutions for flat bar components:

  • Bending accuracy up to ±0.3°
  • Capability for multi-shape parts
  • Wide tooling range for different geometries

Key benefits:

  • Consistent bending angles for assembly fit
  • Flexibility for varying product designs
  • Reduced manual handling

VaskiSHAPE

End Finishing and Edge Preparation

Flat bar end shaping for safe and precise connections:

  • Milling of round or straight ends
  • Burr removal and edge finishing
  • Consistent quality across high volumes

Key benefits:

  • Improved electrical safety
  • Better fit for insulation and assembly
  • Repeatable finishing quality

Discuss Your Manufacturing Requirements

We can help you streamline the manufacturing of data centre components with fully automated flat bar processing solutions. Let’s discuss how to optimise your production for the specific needs of the industry.