Springs and metal parts for the e-mobility sector
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Springs and metal parts for the e-mobility sector

E-Mobility

Boosting the new mobility

Electrification is reshaping mobility, from electric and hydrogen cars to e-bikes, scooters, and charging infrastructure. RPK Group engineers the connection and motion components these platforms depend on: custom flexible bus bars built to your resistance, vibration, and thermal targets on dedicated automated lines, plus contact and canted coil springs for connectors and chargers and springs for battery and drive systems. We co-develop each part with your engineers and validate it before volume production.

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Spring, bus bar and stamping and bending applications in e-mobility

Electric & hydrogen cars

Electric & hydrogen cars

E-bikes

E-bikes

Electric scooters

Electric scooters

Battery systems

Battery systems

Power connectors

Power connectors

Electric chargers

Electric chargers

Springs, bus bars and metal solutions for the e-mobility sector

Frequently Asked Questions

What is a flexible bus bar, and where is it used in an electric vehicle?

A flexible bus bar is an electrical conductor composed of multiple thin, laminated copper or aluminum layers that can flex and accommodate movement. In an electric vehicle, it connects high-current components such as the battery modules, battery management system (BMS), DC-DC converter, inverter, and charger.

What is the difference between a flexible bus bar and a rigid bus bar?

A flexible bus bar uses laminated layers, so it bends, absorbs vibration, and compensates for thermal expansion and tolerance stack-up. A rigid bus bar is a solid conductor suited to static, straight-run power distribution. EV packs usually need the flexible type because cells expand and contract, and the vehicle vibrates constantly.

Can RPK Group customize a flexible bus bar for my application?

Yes. RPK Group defines the material, number of layers, cross-section, geometry, coatings, insulation, and connection interfaces based on your electrical and mechanical requirements, then validates the design in-house. It does not work from a fixed catalog.

Why not just use a cable or a standard busbar?

A cable can add weight and bulk, and a standard busbar sized from a table is often oversized for weight or undersized for current and can add stress at the terminals. A custom flexible bus bar meets the platform's real current, thermal, vibration, and packaging requirements.

Which manufacturing processes does RPK Group use for bus bars?

RPK Group uses stamping, bending, CNC multislide forming, laser welding, laser brazing on pads, insert placement, assembly, and coating on dedicated automated lines.

What other e-mobility components does RPK Group supply?

Beyond bus bars, RPK Group supplies compression, wave, torsion, and contact springs; stamped and bent parts; wire forms; and assemblies for electric and hydrogen vehicles, e-bikes, electric scooters, battery systems, power connectors, and chargers.

How does RPK Group manage heat and vibration in EV power connections?

RPK Group designs the conductor to carry the target current with low resistance while absorbing vibration and thermal movement, so that stress is not transferred to the battery terminals and joints, thereby protecting fatigue life.

Get the most out of our expertise in the E-Mobility industry

Our engineers work alongside our customers to find the best solution for them, applying scientific methods and knowledge accumulated over almost 50 years.

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Do you need help for your next project?

Contact our engineering and sales teams. We will help you find the best solution for your applications.

+34 945 25 77 00

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