Data centers power the digital economy and demand for capacity is accelerating. Global data center capacity is expected to nearly triple by 2030, driven largely by artificial intelligence (Noffsinger et al., 2025). For developers and OEMs, that growth brings tighter construction timelines, higher rack densities, and significantly greater power demands. As electrical loads increase, power distribution systems must perform flawlessly while fitting into increasingly compact, modular designs.

But scaling infrastructure is not just an engineering challenge, it is also an operational one. Managing multiple suppliers for copper sourcing, machining, plating, finishing, and packaging can introduce delays, increase coordination costs, and create opportunities for error. Integrated fabrication and kitting offer a more efficient approach.

By delivering copper busbars and power components fully fabricated, finished, labeled, and packaged for installation, OEMs can reduce handling, simplify procurement, and accelerate deployment. In one recent hyperscale data center program, pre-packaged installation kits reduced on-site labor time by up to 98%, while also minimizing installation errors and compressing build schedules.

As construction cycles accelerate and facilities scale faster than ever, success increasingly depends on how efficiently components move from design to installation. Partnering with a fully integrated supplier like Materials and Manufacturing Services streamlines that process, transforming raw copper into installation-ready power distribution solutions that support faster, more predictable data center growth.

The Scaling Challenge: What’s Holding Data Centers Back

Investment in data centers is increasing and speed of execution is essential. As projects grow in size and require flexibility of last-minute changes, operators and OEMs face pressures that directly affect timelines, cost, and long-term performance.

• Labor constraints and rising costs: Skilled electrical and mechanical trades remain limited. Outsourcing fabrication and finishing reduces onsite labor demands and helps control cost.
• Procurement complexity: Copper demand remains high and supply chains fluctuate. Securing the right alloys at the right time requires reliable sourcing without overextending inventory.
• Handoff risk: Managing multiple vendors increases the chance of errors. A single incorrectly cut or improperly finished component can delay energization and commissioning.
• Pressure to scale: Higher densities, tighter footprints, and faster build cycles require infrastructure that is precise, modular, and built for expansion.

These challenges slow progress and introduce risk. Reduce risk of supply chain fragmentation through integrated material sourcing, fabrication, and logistics. Materials and Manufacturing Services helps stabilize execution and keep large-scale builds on track.

Unlocking Copper’s Full Potential Through Fabrication and Finishing

Copper’s conductivity and thermal performance make it essential in power-critical environments. But raw copper is only the starting point. Its value is realized through fabrication and protective finishing that delivers components ready for installation that are built to last.

Precision Bus Bar Fabrication for High-Density Power

As data centers grow, power infrastructure must keep pace. Busbars need to handle higher current loads with consistent performance. CNC bending and punching allows for tight dimensional control and repeatable tolerances, which becomes more important as rack densities increase and systems operate under greater electrical and thermal stress.

In AI and high-performance computing environments, small inconsistencies can cause excess heat, connection fatigue, or voltage drop. These issues can limit performance and increase downtime risk. Busbars are also central to busway and bus duct systems that distribute power across facilities, where consistency across every section is critical.

Precision fabrication not only supports current load requirements but also allows for future expansion. Custom busbars and assemblies make it easier to integrate higher-density equipment, adjust layouts, and scale capacity without major disruption.

Enhancing Copper Performance with Coatings and Plating

Even in controlled environments, copper components face heat, moisture, and long-term wear. Over time, oxidation and surface degradation can affect conductivity and reliability. Coatings and plating help protect against these risks.

Epoxy coatings add insulation, reduce the chance of arcing, and improve durability. Electroplating with tin, nickel, or silver protects against oxidation and improves surface conductivity. These finishes help maintain stable electrical contact through repeated thermal cycles.

Together, these finishing processes strengthen both the electrical and mechanical performance of copper components, supporting long-term reliability and reduced maintenance.

Smarter Deployment with Custom Kitting

In large-scale builds, speed and organization matter. Bulk shipments require sorting and manual verification onsite, increasing labor, introduces handling damage or misplacement of parts, and the chance of errors. Custom kitting simplifies the process.

Components arrive organized, labeled, and aligned with project drawings and bills of materials. Laser etching, barcoding, and digital labeling make it easier to verify parts quickly and accurately.

The result is faster installation, fewer mistakes, and more predictable timelines. For operators bringing new capacity online, better coordination helps keep projects on schedule.

Why a Vertically Integrated Partner Matters

Each additional vendor in the supply chain adds complexity. Separate providers for sourcing, fabrication, finishing, and logistics create delays and increase the chance of miscommunication. When uptime and precision are critical, those gaps affect both cost and schedule.

A vertically integrated model simplifies the process. By managing material sourcing, fabrication, finishing, and logistics under one roof, Materials and Manufacturing Services reduces handoffs and strengthens accountability. One coordinated team replaces multiple vendors.

This approach has clear advantages:

• Shorter lead times: Integrated production and logistics keep projects on schedule.
• Consistent quality: Central oversight maintains uniform standards across every component.
• Lower total cost: Fewer transfers reduce handling, transportation, and administrative expenses.
• Greater reliability: Clear ownership across the whole process supports predictable delivery.
• Scalable capacity: Integrated operations adapt more easily to higher volumes and evolving project needs.

The result is a more dependable supply chain and a smoother path from design to installation.

Powering the Digital Economy Forward

Digital growth depends on infrastructure that can scale quickly and perform reliably. Every new cloud region, AI deployment, and hyperscale expansion requires power distribution systems built for higher density and tighter timelines. Execution now matters as much as design.

For data center OEMs, that means partnering with teams who understand how each component fits within the larger system and can deliver it ready for integration. Materials and Manufacturing Services supports customers from early alignment through final delivery, transforming copper into fabricated, finished, and kitted components that match build requirements.

The outcome is fewer handoffs, reduced inventory complexity, shorter assembly times, and greater confidence at installation. As demand accelerates, the advantage will go to OEMs who can move quickly without compromising reliability.

Planning your next expansion? We are ready to support your power infrastructure from material to finished component.

References

Noffsinger, J., Patel, M., & Sachdeva, P. (2025, April 28). The cost of compute: A $7 trillion race to scale data centers. McKinsey & Company. https://www.mckinsey.com/industries/technology-media-and-telecommunications/our-insights/the-cost-of-compute-a-7-trillion-dollar-race-to-scale-data-centers

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