High Power Electric Vehicle Busbar Market Size - By Material, Analysis, Share, & Growth Forecast, 2025 - 2034

High Power Electric Vehicle Busbar Market Size

The global high power electric vehicle busbar market size was valued at USD 467.5 million in 2024 and is estimated to reach the value of USD 3.32 billion by 2034, growing at a CAGR of 20.8% from 2025 to 2034. Governments worldwide are applying stringent emission laws and offering extensive incentives to advocate the acceptance of electric vehicles, thereby driving the demand for high-power EV busbars and other components globally. For instance, in January 2024, the U.S. DOE decided to invest around USD 325 million to improve EV charging technology and infrastructure, which directly improves the demand for power distribution components such as busbars and relevant components.
 

Improvements on busbar materials, especially with the incorporation of aluminum and copper, are optimizing the efficiency and performance of high-power EV busbars. For electric vehicles, the enhanced performance that comes with using copper drives its preference due to its superior electrical conductivity and thermal stability. Moreover, the EV battery busbars are also playing a crucial role in the industry vie delivering sustainable performance by adding high tech batteries.
 

Progresses in busbar materials, most notably the employment of copper and aluminum, are improving the efficiency and performance of high-power EV busbars. The higher electrical conductivity and heat stability of copper make it an attractive option for high-performance electric vehicles.
 

High-power EV busbars play a critical role in connecting and controlling the flow of electricity between electric drive systems, battery modules, and power electronics. As there is rapid urbanization, there is greater demand for two-wheelers applied in last-mile logistics, delivery vans, and electric buses, which depend on high-power, dependable energy systems. The high current loads demanded in such applications call for robust and efficient busbar systems constructed from high-end materials like laminated copper or aluminum. The fact that they can minimize system weight without compromising performance is critical to extending vehicle range and overall efficiency.
 

In April 2025, the industry heavily influenced by the U.S. government’s trade tariffs. High tax will be levied on imports from China which sorely impact the industry. Owing to some global political issues, tariffs against other emerging markets have been stalled for a couple of months. As a result, this will lead to increased production expenses for U.S. producers, which will most likely increase the market price and disrupt supply chains. Many companies within the industry will seek out other suppliers or even domestic manufacturing in an attempt to resolve those problems.
 

High Power Electric Vehicle Busbar Market Trends

The growing prevalence of electric vehicles (EVs) across the globe is greatly increasing the need for high-power electric vehicle busbars. As countries shift to more sustainable modes of transport, electric mobility is at the center of government and service sector attention. For instance, in 2023, the International Energy Agency (IEA) reported that global sales of electric cars reached 14 million units representing a 35% growth over 2022 sales. This figure underscores the expansion of support, in addition to the preferences of consumers who are beginning to shift to clean energy options.
 

The growth of investments both from the private, public as well as in charging infrastructure are advancing the growth is influencing the global demand I recent yeras. For instance, the EU’s Fit for 55 package advocates for an aggressive approach for promotion of zero-emission vehicles. This is for a significant drop in greenhouse gas emissions, intending to reach a 55% reduction by 2030.
 

The U.S. Inflation Reduction Act passed in 2022 allocates billions for domestic production of EVs and sourcing battery components. OEMs are now adopting more modular and scalable designs for busbars to improve cost and efficiency as EV production increases. There is also high growth potential in the electric commercial vehicle subsector, comprising of electric buses and delivery vans; this increase in scope drives the demand for high power busbars required for heavy duty power loads.
 

The strengthening consumer interest in high-performance electric vehicles is driving the demand for high power EV busbar systems. EV consumers seek beyond positive environmental impacts; they want high-performance acceleration, longer driving range, and shorter charging times. All these power system requirements demand greater electrical capacity. Sophisticated electrical systems with 400V and sometimes even 800V or higher bus-strung batteries are employed in commercially available high-end EVs including Tesla Model S Plaid, Lucid Air, and Porsche Taycan.
 

High Power Electric Vehicle Busbar Market Analysis

• The global market for high power electric vehicle busbar was evaluated at USD 261.4 million, USD 353.3 million and USD 467.5 million in 2022, 2023, and 2024 respectively. The market has grown recently because of technological, economic, and policy innovations. Improved infrastructure supporting the charging of electric vehicles led to an increase in adoption at a global scale.
   
• Many nations are pledging to shift to all-electric buses and decommission fossil fuel-powered vehicles, which is intensifying the need for electric buses. The shift towards buses with increased functionality also fuels this demand. Commercial manufacturers are upgrading their models and making them more powerful for increased competitiveness.
   
• For instance, in March 2025, Tata Steel Meramandali (TSM) at Narendrapur village in Dhenkanal district initiated its 20 new electric buses as an expression of the Company's drive towards sustainable and green transport for its workforce. The newly designed EV Bus infrastructure features two charging stations, each given with 12 charging points, along with storage rooms, four maintenance pits, and an administrative building that incorporates multiple washrooms and offices.
   
• Increased power output makes it easier to efficiently charge them. Using advanced rod systems allows for enhanced energy efficiency and allows easier access to high levels of current, reducing energy expenditure. They will support parasitic current with zero thermal conductivity loss. All these improvements add construction, installation, and manufacturing speed without increasing production expenses. To OEMs and first tier manufacturers, these changes greatly decrease complicated systems that improve drives enabling simple high-level exploitation devices, marking them easy to access.
   

• The material-based market is divided into copper and aluminum, where aluminum segment held a market share of more than 70% in 2024. Recent extension in the automotive industry is expected to drive the market demand for high power electric vehicle busbar globally.
   
• Copper possesses unique qualities about its electrical conductivity, thermal stability, and strength which makes it the most suited option for high power EV (Electric Vehicle) systems. EV buses are equipped with power EV systems which require heavy current to be transmitted in an efficient and safe manner. Such systems will continue to evolve with advanced driver systems along with improved voltage systems and will require parts that can endure intense levels of energy with minimal loss. Hence, copper busbars are an ideal solution.
   
• For instance, in March 2025, Volvo debuts the Volvo 7800 Electric in Mexico which is the first domestically manufactured electric articulated and bi-articulated bus. It is an electric bus based on the electromobility Volvo BZR platform by Volvo Buses and is set to revolutionize the BRT systems in Mexico by making them more efficient and sustainable systems for mass transportation.
   
• Aluminum increasingly dominates the high-power electric vehicle (EV) busbar industry because of its light weight, cost-effectiveness, and advanced metallurgical developments. Although copper is still predominant in conductivity, aluminum has proven to be a strong contender in EV use where vehicle weight and manufacturing cost savings are paramount. Aluminum provides a strong combination of electrical performance and economic value in high-power busbars, rendering it particularly well-suited to volume EV production.
   

• The U.S. high power electric vehicle busbar market was valued at USD 23 million, USD 33 million, and USD 46.6 million in the year 2022, 2023, & 2024 respectively. The U.S. specifically has witnessed an increase in the sales of electric vehicles, with more than 1.5 million EVs sold in 2023, which is a notable rise compared to past years. This increase is accompanied by significant investments in EV infrastructure, such as the development of public charging networks and incentives for EV makers in North America.
   
• Europe high power electric vehicle busbar market is witnessing robust growth due to severe emission standards and huge government subsidies. This is being led by the efforts initiated by the upcoming nations including Germany, France, Italy etc. In addition, The EU will see a dramatic drop in greenhouse gas emissions, where it has the ambition to be net-zero in 2050 will also be impacting the demand for busbars as it is heavily being adopted in the electric vehicles.
   
• China, Japan, and South Korea are at the helm of EV manufacturing and adoption in Asia Pacific, which is considered a highly energetic region for the high-power EV busbar market. For instance, in 2024, The zero-emission trucks and buses units in China seems to be thriving, operating over 230,000 units. Supporting governmental policies like subsidies and incentives for EV producers have fostered strong advancement in the industry.
   
• The Middle East & Africa market is becoming an important contributor in the high-power EV busbar industry, bolstered by the efforts of the government and investment in infrastructure. As a reference, Qatar runs a fleet of 741 electric buses, contributing to the lowering of emissions in the region as well as boosting sustainable transport.
   
• Latin America is experiencing a slow but consistent growth in the high-power EV busbar industry, driven by urbanization and green consciousness. Chile is taking the lead in the region with one of the largest electric bus fleets in Latin America, working towards complete electrification of its public transport by 2040.
   

High Power Electric Vehicle Busbar Market Share

The top 5 companies in the high-power electric vehicle busbar industry include Legrand, Mersen, Schneider Electric, Siemens and TE Connectivity covering for over 30% market share. The key corporations have delivered enhanced products to the applications, along with other collaborating organizations, invested in technology development, particularly in busbar development which is in turn complemented by investment across the globe.
 

Their dominance of key markets, combined with worldwide alliances, agreements, broad agreements, and unrelenting technological advancements as well as strong product portfolios, benefits them significantly in attaining along with sustaining their aggressive position in the market. As a reference, in January 2023, Automotive Cells Company (ACC), a joint venture between Stellantis and TotalEnergies/Saft and Mercedes Benz, selected Mersen for the supply of smart laminated busbars over for the new busbar refitting model in Europe, targeting enhanced electrifying vehicle power systems.
 

High Power Electric Vehicle Busbar Market Companies

• Legrand is an international expert in electric and digital building infrastructures, proposing a large portfolio of products and solutions for homes, offices, and industries. They specialize in wiring devices, cable management, home automation, and other associated technologies. It has operations in more than 180 countries, manufacturing facilities in 90 countries, and a keen existence in major markets. It generated over USD 9,797.62 million revenue in 2024, driven by a strong global presence.
   
• Schneider Electric is a French multinational company based in Rueil-Malmaison, France. They focus on digital automation and energy management and provide solutions for homes, buildings, data centers, infrastructure, and industries. The mission of the company is to be a digital partner for efficiency and sustainability and spearhead digital transformation through combined process and energy technologies. In 2024, the company generated a revenue of USD 43.2 billion driven by the new launches in the global market.
   
• Siemens is a German multinational technology corporation operating in the industries of industry, mobility, infrastructure, and healthcare with the aim to change the day-to-day via technology. In recent 2024, it has managed to generate approximately USD 39.1 billion.
   
• TE Connectivity is a worldwide industrial technology leader that excels in sensor and connectivity solutions. They supply products and services to various industries, such as transportation, renewable energy, data centers, and medical technology. The mission of the company is to make the future safer, sustainable, productive, and connected by facilitating the distribution of power, signal, and data. In 2024, it made around 15.8 billion by delivering products and services worldwide.
   

Key market players operating across the high-power 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
• Weidmuller Interface GmbH & Co. KG
   

High Power Electric Vehicle Busbar Industry News

• In April 2025, Shinsung ST verifies that it has been enrolled as an official unite to a global electric vehicle producer and secured an order to provide busbars. It is a rare direct contract with an car manufacturer for a battery component maker.
   
• In December 2024, Coleshill-headquartered Sertec Group, a top global components producer specializing in automotive Body in White (BIW) and electric vehicle (EV) products, has financed around USD 9.3 million in its production and part of this is a new 800T machine press, which will improve the company's production capacity
   
• In February 2025, India's electric vehicle policy, which provides import tax relief to foreign manufacturers investing in the nation, will limit them from utilizing funds spent on charging stations for such benefits, enhancing their car production, a government document reveals.
   
• In August 2024, E Daddy, a UAE-based company producing two-wheeler electric vehicles (EVs) in the country, has secured USD 15 million in funding. The capital will drive the company activities towards becoming an established EV maker in the UAE and broader GCC and Africa, which in turn will augment the product adoption in the country.
   

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

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Market, By Material

• Copper
• Aluminum

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

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