Busbar Supports: 3 Powerful Tips for Panel Builders
Inside every safe and efficient electrical panel, there’s a small part doing a big job — the busbar support. It may not stand out, but it plays a key role by holding live conductors in place, keeping safe distances between them, and protecting the system from damage during short circuits.
If you’re a panel builder, OEM, or electrical engineer, choosing the right busbar support is important. It can make a big difference in how reliable and long-lasting your panel is. In this blog, we’ll explain the different types and materials of busbar supports — and share 3 powerful tips to help you pick the right one for your project.
What are Busbar Supports?
Busbar supports are insulating mounts used to secure copper or aluminum busbars inside electrical panels. Their main roles include:
- Providing mechanical support to busbars
- Ensuring insulation from the metallic enclosure
- Maintaining clearance & creepage distances
- Withstanding thermal stress and short-circuit forces
Despite their size, they are essential for long-term performance, safety, and compliance with standards like IEC 61439.
Types of Busbar Supports?
Panel layouts vary, and so do support designs. Here’s a quick overview of the most widely used types:
1. Single Pole Supports
- For individual phase
- Ideal for modular layouts and compact panels
2. Three-Pole & Four-Pole Supports
- Designed for 3-phase and neutral configurations
- Maintains perfect spacing and alignment
3. Stacked / Multi-layer Supports
- Used in high-current or vertical riser systems
- Saves space in narrow panels
4. Custom CNC-Machined Supports
- Tailored for unique layouts
- Offers perfect fit and optimized footprint
At Mayar MJ, we offer all of the above — and even customize them via CNC and thermoforming to match your exact panel needs.
Materials Used in Busbar Supports
Choosing the right material directly impacts support performance. Here are some of the top industry materials:
| Material | Key Traits | Use Case |
|---|---|---|
| DMC (Dough Molding Compound) | Flame-retardant, high strength | Common in LV panels |
| SMC (Sheet Molding Compound) | Tougher, better surface finish | Used in MV panels |
| FRP (Fiber Reinforced Plastic) | Corrosion-resistant | Ideal for custom panels |
| Polycarbonate / PA | Light-duty insulation | Compact/DIN panels |
3 Powerful Tips for Panel Builders
With the technical foundation covered, let’s dive into the three most powerful, field-tested tips for selecting the right busbar supports.
1. Choose Heat and Short-Circuit Resistant Supports
With the technical foundation covered, let’s dive into the three most powerful, field-tested tips for selecting the right busbar supports.
Busbars generate heat during load flow, and in case of faults, mechanical forces spike. Inferior supports crack or deform.
What to Look For:
- 150°C+ thermal endurance
- Flame-retardant (UL 94-V0 rating)
- Certified short-circuit strength
Why it Matters: Supports that fail under heat can cause electrical fires or downtime — both costly and dangerous.
2. Match the Support Design to Your Panel Configuration
From horizontal layouts to vertical risers, the support must align with your bar geometry.
Key Factors:
- Number of poles (1P, 3P, 4P)
- Busbar size and spacing
- Mounting method (screw, rail, snap-fit)
- Clearance based on system voltage
Why it Matters: Misaligned supports lead to stress on bars, poor contact, and difficult maintenance.
3. Source from Trusted, Supportive Manufacturers
Technical specs are only half the story. Choose manufacturers who:
- Offer batch-tested, ISO-compliant products
- Support custom designs for tight enclosures
- Provide documentation like test reports and data sheets
Why it Matters: A reliable supplier saves you time, ensures consistency, and helps you scale confidently.
Why Mayar MJ?
As a leading GCC-based manufacturer, Mayar MJ supplies precision-engineered busbar supports trusted by top OEMs and panel builders. Our advantages:
- Wide range of DMC/SMC supports
- Custom CNC and thermoformed solutions
- Fast delivery across the GCC, Africa, and Asia
- Exclusive dealership for Namsung Busbar Machines
Final Thoughts
Don’t let a small part become a big problem. By focusing on material quality, design fit, and supplier reliability, you can build panels that are:
- Safer
- Smarter
- Longer-lasting
📞 Need Technical Guidance or Samples?
We’re here to help you choose the right support for your project.
👉 Contact us at info@mayarmj.com or visit www.almayarmj.com
