An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.