How to protect the insulation material Mylar covering the busbar from damage when the busbar is bending?

The traceless bending mold has functions such as controlled bending angle, adjustable bending radius and more precise force application. It can bend the busbar without leaving any marks, scratches or deformation on the surface, so when bending the busbar, Using a traceless bending mold is the best solution to protect Mylar (the insulator-covered material) from…

Many of our customers ask us this question when purchasing a busbar processing machine: How should I avoid damaging the Mylar insulator material covering the busbar when bending? Of course, as a busbar machine manufacturer, we have rich experience in busbar machine manufacturing. We have complete solutions for this kind of technical problem. Before answering this question, let us first understand what effect the insulator material Mylar has on the busbar.

The role of insulation material Mylar on busbars

Mylar is renowned for its excellent insulation properties, durability, and chemical stability. It is a biaxially-oriented polyethylene terephthalate (PET) film, which means it is stretched in both the machine direction and transverse direction, providing it with high strength and dimensional stability. The integration of Mylar in busbar systems brings several benefits:

  1. Electrical Insulation: Mylar’s high dielectric strength provides effective electrical insulation between busbar conductors. This is crucial in preventing short circuits and electrical leaks, especially where busbars are closely spaced or stacked in multi-layer configurations.
  2. Thermal Management: In systems where high currents are transmitted, busbars can generate significant amounts of heat. Mylar’s ability to withstand high temperatures ensures that it remains a reliable insulator even under such thermal stress.
  3. Physical Protection: Mylar serves as a physical barrier protecting busbars from environmental factors, such as moisture and chemical vapors, which could otherwise lead to corrosion or degradation of the busbar material, typically copper or aluminum.
  4. Space Efficiency: Because Mylar is available in thin films, it does not add significant bulk to busbars, allowing for more compact and space-efficient designs in electrical panels and distribution systems.

Solutions from our clients

After understanding the effect of the insulating material Mylar on the busbar, let’s take a look at how our customers solve the problem of “avoiding damage to the insulating material Mylar covering the busbar when bending”.
We found that our customer added an extra layer of insulating material Mylar in the middle of the bending mold, and the insulating material Mylar covering the busbars was damaged to a minimum extent. This can be considered a better solution. However, this solution does not completely solve the problem of “avoiding damage to the insulating material Mylar covering the busbar”, and it will reduce the efficiency of busbar bending, and the quality and accuracy of bending will also be greatly affected.

Why is the insulating material Mylar covering the busbar damaged?

If we want to solve the problem of “avoiding damage to the insulating material Mylar covering the busbar when bending”, we must know the reason why the insulating material Mylar is damaged. We know that traditional busbar bending dies have been the industry standard for many years. However, traditional bending dies often exert significant stress on the material, causing bending points to deform. Additionally, the pressure exerted during the bending process may leave marks or scratches on the surface of the bus bars, which are not only unsightly but may also act as corrosion points over time.

Our solution: Use traceless bending molds

After knowing the reason behind the damage of the insulating material Mylar, we can solve this problem by using a traceless bending mold. Traceless busbar bending dies use a more sophisticated mechanism that minimizes the stress and deformation typically associated with traditional bending.
  • Conventional bending mold

  • Traceless bending mold

Economic Considerations

The adoption of traceless busbar bending technology involves a higher initial investment in terms of both the equipment and training required to operate it effectively. However, this can be offset by the reduction in waste and rework costs. Since traceless bending reduces the risk of damage during the bending process, the overall quality of the output is higher, potentially reducing the need for costly quality control measures and rework.


Mylar’s role in busbar insulation is critical to maintaining the safety, efficiency and reliability of electrical systems. Its excellent material properties, such as high dielectric strength, thermal stability and mechanical durability, make it ideal for busbar insulation. Using a traceless bending mold is the best solution to avoid damage.

If you have a better solution to solve the problem of busbar insulation polyester film being damaged during bending, please contact us to exchange opinions.

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