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Braided Power Conductors
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These components act as flexible copper power connectors in electrical systems where reliable high-current transfer and mechanical flexibility are required.
Elexo braided power conductors are engineered to ensure reliable high-density current transfer in critical power infrastructures where electrical performance, thermal stability and mechanical integration are essential, acting as flexible joints within complex electrical systems, including busbar systems and power distribution architectures.
These flexible power connections are commonly used in transformers, switchgear, inverters, energy storage systems, photovoltaic and wind power plants, hydrogen production facilities and data center power infrastructures, supporting flexible power distribution across modern energy systems.
Manufactured from high-conductivity Cu-ETP copper wires, these flexible connectors provide excellent electrical conductivity, optimized contact resistance and long-term stability under continuous load conditions and thermal cycling.
With cross sections ranging from 10 mm² up to 5,000 mm² and current ratings exceeding 6,000 A, Elexo braided conductors are designed for compact installations where space constraints, vibration resistance and installation flexibility are decisive factors.
APPLICATIONS
Elexo braided power conductors are widely used in:
• Power transformers and generator connections
• Busbar systems and bus duct interconnections
• Low and medium voltage switchgear
• Rectifiers and high-power converters
• Industrial inverters and UPS systems
• Battery Energy Storage Systems (BESS)
• Photovoltaic and wind power infrastructures
• Hydrogen production and electrolysis plants
• Data center power distribution and mission-critical rooms
• Railway and heavy industrial power installations
• Flexible busbar connections for compact power distribution systems
They are particularly suitable for installations requiring:
• High current density in limited space
• Reduced mechanical stress on terminals, rigid busbars and power distribution assemblies
• Compensation of vibration and thermal expansion
• Stable electrical performance over time
• Custom drilling patterns and integration with OEM layouts
ENGINEERING FLEXIBILITY
Beyond standard solutions, Elexo develops fully customized braided conductors according to customer drawings and specific installation requirements supporting modular and scalable electrical and busbar system architectures.
Customization options include:
• Terminal widths from 8 to 200 mm
• Standard or custom drilling patterns (DIN 43673 available)
• Bare, tin-plated, silver-plated or nickel-plated terminals
• Hot tin dipped terminals (HTD) for enhanced corrosion protection
• Special braid structures and materials
• Multiple insulation options (TPE halogen-free, silicone, PVC, fiberglass and others)
Each solution is engineered to comply with IEC current load standards and specific thermal rise requirements, ensuring reliable operation in demanding power applications
WHY ELEXO
At Elexo, braided conductors are not simply flexible connections.
They are engineered current transfer systems designed to integrate reliably within complex electrical and busbar architectures.
Thanks to our experience in renewable energy, data centers, heavy industry and energy transition technologies, we support OEMs, EPC contractors and system integrators from concept validation and application engineering through to serial production.
Elexo braided conductors are increasingly used as flexible alternatives to rigid copper busbars in mission-critical power infrastructures.
Elexo – Flexible copper connections engineered for systems where energy cannot fail.