Electrical busbar and method of fabricating the same

A busbar for electrically connecting components in a power distribution system, the busbar comprising:

• a plurality of conductors with:
• (i) a first end, (ii) a second end opposite the first end, and (iii) an intermediate portion extending between the first end and the second end, wherein the first end, the second end, and the intermediate portion are integrally formed with one another;
• and
• wherein the intermediate portion includes:
• an edge;
• a surface;
• a partial solidification zone where a majority of the plurality of conductors are fused together using a surface-based fusion process to form a partially solidified region with a surface-based fusion peak, said surface-based fusion peak is positioned a first distance away from the surface of the busbar, and wherein all of the plurality of conductors between the surface and the surface-based fusion peak are fused together to form a single consolidated conductor;
• and
• a fully solidified edge region where the plurality of conductors are fused together using an edge-based fusion process, the fully solidified edge region comprises an interior weld boundary, said interior weld boundary is positioned a second distance away from the edge of the busbar, and wherein all of the plurality of conductors between the edge and the interior weld boundary are fused together to form a single consolidated conductor;
• wherein the second distance is less than the first distance.