Originally Posted by Wood
I imagine shearing it to exact length would not be a problem. What would you use for a punch? Would you still want some elongation?
It can be drilled. They sell an expensive jig for that purpose but it would be very easy to replicate its essential functionality. All the bending, twisting and folding obviously must be done before cutting and drilling/punching.
To allow for elongation between cells (if I'm interpreting your question correctly) I could envisage simply bending a small hump into the connection, though with clamped cells that seems the least troublesome deformation mode. Flexing is most likely the greater concern, and that mode would be accommodated naturally by the flexibar.
In assembling a 4P cell group, the flexibar could be run continuously across the cells, eliminating most of the contact resistance points.