BatteryBee

Busbars

The Busbars tab builds conductive rails and bridges from the painted series assignment. Use it after the pack is contiguous, complete, and locked or otherwise stable.

Prerequisites

  1. Choose the final cell spec and targets.
  2. Finish Geometry, Case, and Layout settings that affect cell slots.
  3. Paint Series lanes until the stats panel shows valid, complete groups.
  4. Resolve weak or missing adjacent links, or plan intentional bridges.
  5. Open Busbars and add at least one busbar layer.

Configuration panel

Busbar layers

Add one or more conductive layers. Each layer has trace width, plate thickness, cap diameter, cap type, material, and color settings.

Cap type

Choose none, slit, or cutout. Slits use length and width; cutouts use diameter.

Enable and reorder

Toggle layers on or off and move them up or down. Only enabled layers are exported.

Flip busbars

Flip front/back assignment per cell layer. Other layers stay unchanged.

Folds panel

Manage fold zones that add bend tails to the flat export. Explicit fold IDs keep output deterministic.

Preview

The 3D viewer shows enabled busbar overlays using the current series metrics, global bridges, layer sides, and folds.

How busbars are exported

  • Frontend code computes busbar rail and bridge segments from the viewer scene and series connection transitions.
  • The internal export service expands those segments into SVG, DXF, or STL geometry.
  • Exports are split per cell layer and front/back side, then split into disconnected outline groups when needed.
  • DXF export uses the geometry engine. If local DXF support is missing or export fails, use SVG for inspection while troubleshooting.
  • STL busbar export has a longer timeout than SVG/DXF because solid generation is heavier.
Busbar resistance estimates
Reports can estimate resistance from busbar layers, manual bridges, temperature, BMS path, and inter-layer link assumptions. Treat estimates as planning inputs, then validate with your real fabrication process.

Troubleshooting

  • Prerequisites pending: Series lanes are incomplete, not contiguous, or busbar eligibility is false.
  • No export files: enable at least one busbar layer and choose a supported format.
  • Unexpected bridges: check the Series stats panel for missing adjacent links and verify layer front/back flips.
  • Folds missing: confirm fold zones are enabled and have selected cells when single-cell folds are used.