The environment of the end application in which the bus bar operates will play a role in determining the type of materials and construction methods used for product fabrication. The main environmental factors are temperature extremes, moisture/humidity, and vibration, but many applications will impose additional concerns.

Another consideration, which is sometimes overlooked, is the type of environment the bus bar and assembled system will be subjected to during transportation. During the design phase the environmental suitability of the following should be considered: conductor material, out gassing, plating material and thickness, inner and outer insulation material, termination method, edge-sealing method, back filling of bushings and conformal coating if used. Choosing the right materials and construction methods will help to assure that the bus bar performs well under the specified environmental conditions.