This research presents an integrated Multiphysics design and analysis of a copper busbar system used in air-insulated switchgear (AIS) under rated operating conditions. The study combines electrical conduction, thermal, and structural analyses using finite element methodology in ANSYS Workbench. Busbar design in switchgear ensures safe, reliable power distribution by balancing current capacity, thermal performance, mechanical strength, insulation, and standards compliance. Ready to Design a Reliable Busbar System? A busbar is a metal bar, usually made of copper or aluminum, that carries. An electric busbar (also written as bus bar) is a metallic bar, strip, tube, or rod that conducts current from one place to another in a safe manner with minimal energy losses. Good busbar design cuts losses, improves reliability, and supports flexible operation in systems like GGD Low Voltage. Additionally, these busbars play a pivotal role in connecting high-voltage equipment within electrical switchyards, as illustrated in Figure 2, and low-voltage equipment in battery banks. Typically devoid of insulation, these busbars possess the necessary rigidity to be supported in the air by. The starting point for planning a switchgear installation is its single line diagram.