Electric Vehicle Busbar Market Size - By Material, By Power Rating, Growth, & Forecast, 2025 - 2034

Electric Vehicle Busbar Industry Market Size

The global electric vehicle busbar market size was accessed at USD 776.1 million in 2024 and is estimated to reach the value of USD 5.30 billion by 2034, growing at a CAGR of 20.4 % from 2025 to 2034. The global transition to electric vehicles (EVs) has fuelled the growth of the EV busbar industry, as such components are essential for effective power delivery within EV battery systems. For instance, the International Energy Agency (IEA) reported that global EV sales exceeded 14 million units in 2023, representing a 35% year-on-year increase, which in turn will complement the business outlook in year to come.
 

Government initiatives that seek to lower carbon emissions have been instrumental in driving the adoption of EVs, indirectly triggering demand for busbars. Direct regulations, including the requirement by the European Union to shift from ICE cars by 2035, and indirect incentives, of the USD 7,500 tax credit for the purchase of EVs provided by the U.S. Inflation Reduction Act, have encouraged automakers to heavily invest in electrification in the economies including the U.S.
 

The growth of EV charging infrastructure globally has considerably driven the busbar market, as these products play a crucial role in controlling high-voltage power transfer in quick-charging stations and electric vehicle charging networks. This higher demand for busbars has also triggered technological development to enhance efficiency and reliability in the charging process, further stimulating growth in the market. In 2023, the government of the U.S. spent USD 5 billion with the National Electric Vehicle Infrastructure (NEVI) program to deploy 500,000 public charge points by the year 2030.
 

The development of vehicle-to-grid (V2G) technology is another driver for the electric vehicle (EV) busbar market since it requires sophisticated power distribution systems with bidirectional energy transfer capability. For instance, Nissan has teamed up with Fermata Energy to implement V2G-ready systems based on custom busbars in its Leaf EVs for bidirectional energy transfer at 19.2 kW.
 

Electric Vehicle Busbar Market Trends

Rising shift towards more superior materials that improve conductivity without adding weight is gaining momentum as the industry seeks to enhance efficiency and performance in EV designs. Conventional copper busbars, while very conductive are heavy and expensive, so manufacturers are considering alternatives, including aluminum and composite alloys. Aluminum busbars, for instance, provide up to 60% weight reduction over copper, an essential benefit for EVs seeking to maximize battery efficiency and range. Composite alloys, on the other hand, offer a combination of strength and lightweight properties that can further enhance the performance of EV busbars.
 

Smart battery management systems (BMS) are driving the demand for smart busbars with real-time monitoring and diagnostic capabilities along with the fact that modern busbars are also increasingly being fitted with sensors to monitor temperature, voltage, and current flow so that proactive maintenance and battery safety are improved. LG Energy Solution, for instance, launched in 2023 its advanced busbar technology featuring embedded sensors that transmit data to BMS to recognize faults and overheat prevention in high-voltage environments.
 

Sustainability has emerged as a key trend in the EV busbar market with producers adopting green manufacturing practices and recyclable materials. This shift towards sustainability is driven by the growing awareness of environmental impact and the need for more eco-friendly solutions in the transportation sector. The European Union's Circular Economy Action Plan, requiring 70% of EV parts to be recyclable by 2030, has sped up this movement. Nexans and Schneider Electric are leading the charge in the application of recycled aluminum and copper in busbars, minimizing virgin material dependency and carbon footprints.
 

Electric Vehicle Busbar Market Analysis

• The EV busbar industry was valued at USD 438 million, USD 589.3 million, and USD 776.1 million in 2022, 2023, and 2024, respectively. Based on material, the industry is segmented into copper and aluminum, where aluminum industry will grow at CAGR of over 21% through 2034.
   
• Dependence on copper busbars for high-performance electric vehicles has bolstered a niche market segment that serves high-power and luxury EVs where efficiency of energy cannot be compromised. With high-performance EVs becoming increasingly in demand, the predominance of copper in the high-performance market will continue to fuel premium market expansion in the long term. For instance, Porsche's Taycan employs copper busbars for its 800-volt design, a move that facilitates high-speed charging and stable power distribution in extreme situations.
   
• The aluminum busbars have been a driving force behind the democratization of electric vehicles with the ability of manufacturers to reduce costs and make more cars for the broader market. Aluminum's lightness also helps with better energy efficiency and overall vehicle performance, which makes it a worthwhile substitute for copper in mass-market EVs. Tesla’s decision to use aluminum busbars in its Model Y structural battery pack, as noted in its 2023 investor report, directly lowered production expenses, allowing the company to offer competitive pricing without sacrificing range.
   

• Based on power rating, the market is broadly segmented into low, medium, and high. Medium power rating industry witnessed a market share of over 33.5% in the year 2024 owing to the increasing demand for high performance EVs with higher power requirements and faster charging capabilities, government incentives, rising luxury EV popularity, and growing demand for electric sports.
   
• The low-power busbar section is significant in making small and entry-level electric vehicles affordable, making new EV consumers in general accessible, so more people can access and utilize electric vehicles in the market with less expensive materials and simpler designs. For instance, the Wuling Hongguang Mini EV utilizes low-power busbars to maintain low costs while still providing assured energy distribution for its small 20-30 kW motor.
   
• Medium-power busbars have become a leading force in the electric vehicle market by enabling mass-market EVs to balance performance with affordability, making them more accessible to a wider range of consumers. For instance, the Nissan Leaf, which uses 110 kW busbars to deliver maximum is a model highlighted in Nissan's 2023 sustainability report to appeal to frugal consumers without compromising key specifications as its practical 240 km driving range.
   
• High-power busbars are revolutionizing the luxury EV market by enabling next-generation technology in the form of fast-charging levels and extended driving ranges. Luxury EV producers will provide high-performance EVs that will eventually fulfill high-demand users' requirements for power with efficiency for their electric vehicles. An example is the Porsche Taycan Turbo S, which is equipped with 800-volt architecture and high-power busbars to enable 270 kW levels of charging, reducing charging time to 22.5 minutes to 5-80% of battery.
   

• The U.S. electric vehicle busbar market was valued at USD 38.5 million, USD 55 million, and 77.3 million in the year 2022, 2023, & 2024 respectively. The market is being driven by federal policies, including the U.S. Inflation Reduction Act (IRA), which provides tax credits to EVs manufactured with domestic content, including busbars. For instance, Tesla’s gigafactory in Texas uses aluminum busbars in its 4680 battery cells for Cybertruck to reduce costs and comply with IRA sourcing rules.
   
• Europe electric vehicle busbar market expansion relies on stringent regulations including the EU's 2035 ICE vehicle ban and the Circular Economy Action Plan, which prioritize the adoption of electric vehicles and sustainable manufacturing practices. This has led to increased demand for EV busbars in Europe as manufacturers strive to meet these regulations and reduce their carbon footprint. For instance, automaker Volkswagen is spending USD 52 billion on electrification by 2026, driving demand for premium busbars in vehicles the ID.4, which uses copper busbars for fast charging.
   
• The Asia-Pacific region dominated in busbar business catering to over 62% market share in the year 2024. In addition, with China's NEV requirement, that mandates 40% EV retail by 2030 is further driving significant growth in the region. The Chinese OEMs BYD utilize cost-effective aluminum busbars to satisfy the objectives as they aim to achieve lightweight and efficiency in vehicles also, their emphasis on low-cost volume EVs creates the biggest volume consumer of busbars, while local producers, including CATL, produce more to catch up with the demand.
   
• The Middle East & Africa electric vehicle busbar market is in its nascent stages but steadily growing due to increasing urbanization and industrialization in the region, with a focus on renewable energy projects driving demand for busbars as more countries in the region invest in infrastructure development and renewable energy sources. For instance, Saudi Arabia's Public Investment Fund (PIF) has signed a deal with Lucid Motors to build a USD 3.4 billion EV factory, which will employ locally made busbars to support production.
   
• The market in Latin America is driven by Colombia's EV tax credits and Brazil's Rota 2030 policy, which have encouraged the adoption of electric vehicles in the region. Colombia's tax credits provide up to 50% off the purchase price of an electric vehicle, while Brazil's Rota 2030 program offers tax breaks for automakers investing in research and development of electric vehicle technology. These initiatives have fueled growth in the electric vehicle market in Latin America, making it one of the fastest-growing regions for EV adoption globally.
   

Electric Vehicle Busbar Market Share

The top 4 companies, TE Connectivity, Siemens, Schneider Electric, and Amphenol Corporation together controlling about 35% of the world market. These players use their knowledge of electrical systems, strategic alliances, and investments in sophisticated manufacturing to dominate the market. Their partnerships with automakers, battery manufacturers, and governments have established them as key enablers of effective power distribution in electric vehicles.
 

TE Connectivity is among the leading companies, with its high-performance busbars specifically designed for EV battery systems and charging infrastructure, along with their Coolbit Aluminum Busbars which are popular among automakers including Tesla and BYD due to their lightweight nature and better thermal management, which allows charging at a faster rate and longer battery life. For instance, TE's collaboration with CATL to create modular busbars for future-generation batteries marks its position in EV production scale-up and increase its global manufacturing footprint and focus on R&D guarantee leadership in fast-growing markets.
 

Electric Vehicle Busbar Market Companies

• Siemens AG, with revenue of USD 89 billion and based in Munich, Germany, is a world leader in EV charging infrastructure, with its forward-thinking busbar systems being the basis for high-power DC fast-charging systems. Its Surcharge UC 350 charging terminals, which are widely installed across Europe and the United States, have patented copper busbars designed to handle impressive 350 kW power loads, supporting fast charging of top EVs.
   
• Schneider Electric SE, based in Paris, applies its sustainable energy management expertise to deliver innovative busbar solutions for electric vehicles and charging networks. Its EcoBusbar line, constructed from 90% recycled aluminum, is a key part of General Motors' Ultium battery platform, significantly reducing production costs and carbon emissions. Schneider has partnered with NIO in China to build battery-swapping stations with high-efficiency busbars to address the region's need for fast, scalable charging infrastructure.
   
• Amphenol Corporation, based in Wallingford, Connecticut, produces high-voltage busbars for high-end EVs, catering to premium vehicle manufacturers including Rivian and Lucid Motors. Amphenol's PowerLok busbars, central to Lucid's market-leading 900-volt architecture, minimize energy loss with ultra-low resistance, enhancing vehicle economy and range. Amphenol's acquisition of MTS Systems in 2023 boosted its testing capabilities, guaranteeing busbar reliability under extreme heat and mechanical stress.
   

Some of the key market players operating across the electric vehicle busbar market are:

• Amphenol Corporation
• Brar Elettromeccanica SpA
• EAE Group
• EG Electronics
• EMS Group
• Infineon Technologies AG
• Legrand
• Littelfuse, Inc.
• Mersen SA
• Mitsubishi Electric Corporation
• Rogers Corporation
• Schneider Electric
• Siemens
• TE Connectivity
• Weidmüller Interface GmbH & Co. KG
   

Electric Vehicle Busbar Industry News

• In January 2025, Tesla revealed plans to build a lower-priced Model Y in Shanghai, with manufacturing beginning mid-2025. The product innovation involves cost-effective busbars, seeking to reduce manufacturing costs by at least 20% and preserve Tesla's competitive advantage in China's electric vehicle market.
   
• In June 2024, Nyoboltlt, a battery start-up, has unveiled an EV prototype with 80% charging in 4 minutes and 37 seconds, as reported by technology news channels. This achievement, thanks partly to optimized busbar technology, offers a driving range of up to 120 miles and might transform EV usage by cutting the time it takes to charge cars dramatically.
   
• In May 2023, a collaboration was established between Urban Mobility Systems (UMS) and Ampowr, reported in European business news to create innovative energy storage technologies, including new busbar designs for enhancing EV performance in different industries. This cooperation reflects the move towards more stable electrification infrastructure.
   

This electric vehicle busbar market research report includes an in-depth coverage of the industry with estimates & forecast in terms of revenue in USD Million from 2021 to 2034, for the following segments:

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By Material

• Copper
• Aluminium

By Power Rating

• Low
• Medium
• High

The above information has been provided for the following regions and countries:

• North America
  • U.S.
  • Canada 
• Europe
  • Norway
  • Germany
  • France
  • Netherlands
  • UK
• Asia Pacific
  • China
  • India
  • Japan
  • South Korea
  • Singapore
• Middle East & Africa
  • Saudi Arabia
  • UAE
  • South Africa
• Latin America
  • Brazil
  • Argentina