The flexible busbar needs to be cured in the connection part to connect (attach) it to a standard cable or connector. In some cases, the connection and solidification of cables or terminals can be accomplished by one-step welding. Depending on the overall dimensions of the flexbus, ultrasonic metal welding can be a high quality, economical solution. Using the torsion welding process, cross-sectional materials of up to 200 mm² can be welded. This welding technique prevents the joining material from hardening, which can lead to material embrittlement and significant changes in material properties.
In some applications the bus bars are soldered to the orange cables which will be soldered to the current connectors. Welding short cables at both ends may result in inconsistent weld quality, as the first weld may be weaker due to vibrations caused by the second weld. USCAR-38 requires testing of cables less than 500 mm in length. Using torsional welding provides such a gentle vibration that studies have shown much less impact on stranded cables and flex busbars, depending on the terminal design. This allows for shorter cables and proper connectors to be soldered together.