[boji]

Does anyone think there's a better material out there I should be looking for to mill so as to suspend bus bars?

Thanks for your input.

https://www.amazon.com/Plastic-Thick-Width-Tolerance-Natural/dp/B07JGDLJYS

[ruffrecords]

I think I would be tempted to use nylon rather than ABS but I have no idea if it is available in the form you need.

Cheers

Ian

[boji]

Ok, but why Nylon?
https://www.ebay.com/itm/Natural-Delrin-Acetal-sheet-block-lot-2-pieces-CNC-Mill-Sizes-In-Description/163908290904

There's also UHMW (Ultra High Molecular Weight Polyethylene) and HDPE

[Tubetec]

Surely there must be something 'off the shelf' from electrical supply sources made specifically for the job you want to do ,
Many other types of terminal blocks and stand-offs around , shouldnt really be a need to turn it into an engineering job .
Having said that ,if you have the time , inclination and dedication theres nothing cant be done .  White nylon stand offs with brass thread inserts at either end (see below).  Some of the other materials you mentioned might have more stable characteristics with regards temperature and voltage , probably wont matter in your application .
 

[ruffrecords]

Ok, but why Nylon?
https://www.ebay.com/itm/Natural-Delrin-Acetal-sheet-block-lot-2-pieces-CNC-Mill-Sizes-In-Description/163908290904

There's also UHMW (Ultra High Molecular Weight Polyethylene) and HDPE

Its tough and back in the days of CRT monitors it was available in UL approved form so flame resistant.

There are almost certainly modern/better equivalents but I would suggest ABS is not one of them.

Cheers

Ian

[shabtek]

For power distribution bus bar mounting  and rigid barriers fr4/bakelite/garolite or similar resin reinforced glass  material is used.
Works for buss bars too.

Mcmaster Carr has sheets angles channels rods etc.
Kinda nasty to machine, dust and fumes are bad. 

Why not use those strips with solder tags like oldskooler DaveP?

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