Copper PCB Busbar Design with bms sense points

I have a Nissan Leaf 14s4p battery pack that requires a purpose-built PCB busbar. The board’s job is to move current, battery sense points to add a bms and the copper architecture must safely carry a continuous 101 A – 200 A.

The design has to match the Leaf module’s bolt pattern and spacing while using copper as the chosen conductor. Please size the copper pours, layer stack-up, and clearances to meet both the current rating and a nominal pack voltage of 350 V. A small area for an optional fuse or shunt is welcome, but keep the layout as clean and low-impedance as possible.

Deliverables
• KiCad or Altium source files, plus production-ready Gerbers and drill files
• A concise design report with cross-section, copper weight, current-density math, and thermal rise estimates at 200 A continuous
• STEP model of the finished board for mechanical fit-checking against the Leaf module

I’ll supply detailed module drawings and measurements once we kick off. After schematic capture and initial layout review, prompt turnaround on the final manufacturing package is appreciated.