To improve energy efficiency in copper Electrowinning different technologies have been developed. These include electrode positioning capping boards and 3D grids, electrode spacers, and, segmented intercell bars. This paper introduces a design concept to avoid electrode open circuits and reduce contact resistances. The design is based on a female teeth shape for the contacts on the intercell bar. This leads to improved electrode alignment, reduced contact resistances, easier contact cleaning and ensured electrical contact for the electrodes. It results in lower operational temperature for the electrodes, reduced plant housekeeping, increased lifespan for capping boards and higher rate of grade A copper production. Comparative results presented should be a useful guideline for any type of intercell bar. Improvements in production levels and energy efficiency should reach 2% and 3% respectively. A 3-D finite-element based analysis and industrial measurements are used to verify. © 2011 IEEE.