The process involves drilling and forging countersunk holes with controlled geometry in both materials followed by compression of cylindrical rivets into the holes to create strong, form- and force-closed mechanical joints. This paper explores a novel double-flush riveting process for assembling hybrid busbars made from aluminum and copper sheets. Martins1,* 1IDMEC, Instituto Superior Tecnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal;. Busbars are preferentially made of copper due to its high electric conductivity.