Busbar Support & Insulator Bracket — Switchgear
Precision brackets that position busbar supports and insulators inside switchgear: laser-cut and formed from 2–3 mm steel or aluminium, hole centres held to ±0.2 mm, deburred and edge-broken so the insulating component seats without stressing the ceramic. Made by WERIX Metal from SPCC 2.0-3.0mm / DMC insulating material to a tolerance of ±0.1mm, finished with zinc plating or hot-dip galvanizing. Typical order volume is from 500 to 100000+. Free DFM quote within 24 hours.
Engineering drawing available on request
Send your target specifications — we reply with a drawing and a DFM quote within 24 hours.
Busbar Support & Insulator Bracket — Switchgear
Precision brackets that position busbar supports and insulators inside switchgear: laser-cut and formed from 2–3 mm steel or aluminium, hole centres held to ±0.2 mm, deburred and edge-broken so the insulating component seats without stressing the ceramic.
| Part number | P-102 |
|---|---|
| Product type | Busbar Support |
| Industry | Power Grid |
| Material | SPCC 2.0-3.0mm / DMC insulating material |
| Tolerance | ±0.1mm |
| Surface Finish | zinc plating or hot-dip galvanizing |
| Manufacturing processes | stamping · bending |
| MOQ / Volume | from 500 to 100000+ |
Busbar Support & Insulator Bracket — Switchgear: manufacturing notes
Busbar Support & Insulator Bracket — Switchgear has to survive its application, not just its inspection report. This page sets out how the part is actually made — the material decision, the forming sequence and the tolerance strategy — so a buyer or engineer can judge whether the specification matches the application before a drawing is even sent.
Why this part is made in cold-rolled steel
Busbar Support & Insulator Bracket — Switchgear is specified in SPCC 2.0-3.0mm / DMC insulating material. Cold-rolled mild steel is the most predictable substrate in the shop: consistent thickness, tight bend behaviour and a surface that takes powder coat evenly. It has no inherent corrosion protection, so it is normally paired with a coating system, and any cut edge stays protected only as long as that coating is intact.
How the part is formed
The production route for this part is stamping, bending. Stamping moves the cost from the labour line to a hardened die, which pays off from a few thousand pieces upward: cycle time stops being a labour cost and becomes machine time, and every subsequent part inherits the die’s tolerances instead of the operator’s. Below that volume the same geometry is normally lasered and formed. Bending is where most tolerance stack enters a sheet metal part. We set the bend allowance from the part’s own material and radius using the K-factor the press is running, then verify the first article on the machine rather than from the drawing, because springback moves with material batch and grain direction.
What ±0.1mm actually requires on the shop floor
The drawing calls for ±0.1mm. On a part like this that is a process decision, not an inspection decision: it fixes which machine holds the critical features, how the part is fixtured for each operation, and whether a formed feature can be checked after coating or has to be measured before it. We confirm the first article against the drawing and record the values, so the tolerance is demonstrated rather than assumed. If a dimension in your drawing is tighter than this part needs, it is usually worth relaxing it — over-toleranced features are one of the quietest cost drivers in a sheet metal quote.
Finishing: electroplating
zinc plating or hot-dip galvanizing. Plating puts a metallic layer on the part for corrosion protection, conductivity or appearance. Because plated finishes are thin, they follow the surface underneath: a scratch or a forming mark in the substrate shows through, so the finish is planned after the forming sequence rather than specified independently of it.
Frequently asked questions
- What is the minimum order quantity for busbar support & insulator bracket — switchgear?
- The order range for this part is from 500 to 100000+. Below the low end of that range the tooling and setup are spread over too few pieces to be economic, so if you are prototyping we would normally build the first units from the same process route and quote the production quantity separately.
- Can the material be changed to reduce cost or weight?
- Yes, and it is worth asking before the design is frozen. The current specification for this part is SPCC 2.0-3.0mm / DMC insulating material; depending on the service environment, a different grade or a lighter gauge with formed stiffening can meet the same requirement. What we would not do is change the material without re-checking the bend radii, the welding process and the coating system, because all three move with the substrate.
- What finishing options are available for this part?
- The current finish specification is zinc plating or hot-dip galvanizing. Powder coating, anodising, zinc or nickel plating, brushing and blasting are all available in-house, so the finish can be changed without changing supplier — and where the part will be seen, we match colour to the RAL or Pantone reference on your drawing.
- How long does production take, and what do you need from us to quote?
- Prototypes are typically 3–7 business days and production runs 7–15 days once the drawing is released and the finish is confirmed. To quote we need the drawing or CAD file (STEP, DXF, DWG, IGES or PDF), the material and finish, the quantity and the destination — and any tolerance or inspection requirement that is not already on the drawing. You get a DFM review with the quotation, not after it.
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