Copper Stamping, Copper Stamped Components ,Copper Stamped Parts

Precision Copper Stamping Manufacturer From India

At Conex Metals, we are one of the leading manufacturers and exporters of Copper Stamping, Copper Stamped Parts and Copper Components from India. We have been supplying precision-engineered Copper Stamped Products to the world market for many decades, supporting OEMs in Electrical, Automotive, Renewable Energy, Switchgear, Transformer, HVAC, Railway and Heavy Engineering sectors. Our facility combines high-pressure mechanical presses, carbide progressive dies, CNC slotting, annealing furnaces, riveting machines and advanced inspection systems to manufacture tight-tolerance stamped Copper parts with consistent performance.
Our engineering team works closely with customers to optimize drawings, improve manufacturability, reduce weight, and enhance conductivity using the right Copper grade—ranging from high-conductivity ETP Copper to advanced Copper alloys like C11000, C10100 OFC, C17200 Beryllium Copper, C14410 Low-Lead Copper, C12200 DHP, and specialty European (EN), Japanese (JIS), Chinese (GB) and Indian (IS) grades.
This page offers a comprehensive technical guide covering material grades, stamping processes, tooling, tolerances, hot stamping, forging alternatives, plating standards, industries served, dimensional charts, performance metrics, FAQs, packaging, USPs, and international certifications to support your procurement and engineering teams.

Copper Stamped Parts

Copper Stamped Parts are manufactured using progressive or single-stroke stamping dies designed to produce geometrically complex, highly conductive parts used in electrical and thermal applications. Stamped parts typically include Copper terminals, Copper connectors, busbar links, switchgear parts, grounding brackets, transformer segments, battery connectors, EV terminals and micro-precision contact parts. The stamping process ensures repeatability, sharp profile edges, tight burr control (<0.05 mm) and uniform material grain flow, essential in high-current or high-frequency electrical assemblies. These parts are widely used in Automotive wiring systems, Power Distribution Boards, Earthing systems, Renewable Energy, Aerospace electronics and Telecom equipment.

Copper Stamping

Copper Stamping refers to the deformation of pure Copper or Copper alloy sheets using precision dies to obtain specific shapes and dimensional features. This process can involve blanking, piercing, bending, deep drawing, embossing and coining depending on the component design. Stamping is preferred for Copper due to its high malleability, excellent conductivity and ability to maintain dimensional stability even in thin gauges (0.2 mm to 8 mm). High-speed mechanical presses (40–300 tons), progressive die sets, carbide punches and in-die tapping units help produce high volumes with consistent dimensional accuracy. Copper stamping is essential for electrical connectors, relay parts, power electronics, transformer segments, circuit breakers and grounding systems.

Copper Forging

Copper Forging uses compressive force to shape heated Copper billets or slugs, producing parts with improved strength, reduced porosity and directional grain structure. Unlike stamping, forging is suitable for thicker, load-bearing parts such as heavy connectors, mechanical terminals, lugs, busbars, hydraulic fittings and high-stress components. Forging can be Open-Die, Closed-Die or Upset-Forged depending on geometry. This process enhances mechanical properties like fatigue resistance, tensile strength and impact durability, making forged Copper parts suitable for Automotive electrical systems, Marine connectors, Industrial switchgear and High-current power distribution networks.

Copper Stamped Components

Copper Stamped Components encompass a wide range of engineered products manufactured with multi-stage operations—stamping, bending, threading, tapping, plating and assembly. These components include electrical terminals, busbar straps, clips, grounding plates, shunts, battery terminals, earthing clamps, EMI shielding components and HVAC brackets. They are produced using high-accuracy progressive dies, ensuring minimal variation and uniform performance across large batches. Copper Stamped Components are widely used in Smart meters, Solar inverters, Electric vehicles, Consumer electronics, Power backup systems and Industrial automation.

Copper Hot Stamping & Hot Forging

Copper Hot Stamping involves applying heat to soften the Copper sheet before stamping, helping achieve tighter bends, deeper draws and more complex geometries that may otherwise crack at room temperature. This process is ideal for high-ductility alloys, high-strength Copper grades, and components with deep cavities. Hot Forging, on the other hand, uses elevated temperatures (600–800°C) to shape Copper slugs, producing dense and strong components for power distribution units, heavy terminals, transformer connectors, and mechanical couplers. Both methods enhance grain structure, forming flexibility and fatigue strength.

Copper Stamped Terminals

Copper Stamped Terminals are critical electrical contact elements designed for maximum conductivity and minimum heat generation. They include ring terminals, spade terminals, fork terminals, battery terminals, lug connectors, male/female contact terminals, EV terminals, PCB terminals and custom-engineered forms. These terminals are stamped using high-precision progressive dies with in-die bending and coining, ensuring consistent thickness, hole diameter, surface finish and contact area. Copper Stamped Terminals are widely used in Switchgear, Automotive wiring harness, Electric Vehicles, Renewable Energy systems, UPS systems, HVAC and power transmission lines.

Copper Electrical Stamping Work

Copper Electrical Stamping Work includes manufacturing of high-current conductive components such as stator/rotor laminations, busbar links, transformer strips, shunt connectors, power relay parts, switchgear contact plates and power electronics hardware. These components require strict adherence to electrical specifications like conductivity, hardness, temper, surface finish, and thermal performance. In-process controls include conductivity testing, hardness testing, micro-burr inspection, profile measurement and 2D vision inspection. Copper Electrical Stamping is crucial for ensuring low-loss electrical flow across demanding industrial environments.

Material Grades (Global Standards)

Pure Copper Grades

Copper Alloy Grades

Manufacturing Processes & Machinery

Copper Stamped Parts are produced using:
• High-speed Mechanical Presses (40–300 Tons)
• Progressive Dies & Single-Stroke Dies
• In-Die Tapping Units
• CNC Machining & Deburring Machines
• Annealing Furnaces (Controlled Atmosphere)
• Hydraulic Presses for Forging
• Wire EDM & Die Sinking EDM for Tooling
• Automatic Feed Rollers (Servo Controlled)
• 2D/3D Vision Inspection Systems

Typical Parts Produced

• Copper Lugs, Copper Electrical connectors, Copper contact terminals
• Copper busbar, Busbar links & Copper grounding bars, plates
• Copper Battery terminals & Copper EV connectors
• Copper Transformer Connectors, Copper Transformer Spades, copper strips & power relay parts
• Solar inverter connectors
• HVAC and plumbing stamped Copper clips
• Telecom hardware & RF shielding parts

Dimensional Table

Plating & Surface Finish

• Tin Plating (Bright / Matt)
• Nickel Plating
• Silver Plating
• Gold Flash
• Electroless Nickel
• Passivation
• Anti-oxidation Coatings
• Pre-tinned Copper strip stamping

All plating meets ASTM B545, ASTM B689, ASTM B734, EN ISO 4521 etc.

Industries Using Copper Stamped Parts

• Automotive
• Switchgear & Electrical
• Renewable Energy (Solar, Wind, Battery Storage)
• Railways & Metro
• Telecom and 5G Hardware
• Transformer and Power Transmission
• Consumer Electronics
• Aerospace and Defense Electronics

Tolerances

• Flatness: ±0.05–0.10 mm
• Hole Diameter: ±0.05 mm
• Profile Accuracy: ±0.03 mm
• Bend Angle: ±1°
• Burr Level: <0.05 mm

Turnaround Time

Typical Lead Time: 4–6 Weeks depending on die development and production volume.

Performance Metrics

• Conductivity (IACS %)
• Contact resistance
• Mechanical tensile strength
• Dimensional repeatability in large batches
• Thermal load performance
• Fatigue life for terminals

Why Choose Us

With over three decades of global manufacturing and export experience, Conex Metals offers unmatched strengths:
• Highly responsive engineering team that recommends improvements in customer drawings.
• Flexibility in production schedules from prototype to mass production.
• Consistent communication with customers in USA, UK, Europe, Australia, Middle East.
• Ability to supply Copper Stamped Parts with custom packaging, labels, barcodes and palletization.
• Faster turnaround and stable quality backed by strong QA systems (APQP, PPAP, FMEA).
• Ability to manufacture complex tooling in-house via EDM and CNC.

Packaging & Shipping

• Export-grade corrugated boxes
• Heat-sealed polythene bags
• Custom branding & private labels
• Wooden pallets / fumigated crates
• Global shipping via air, sea and express couriers

Customer Testimonials

John M., USA – “Consistent quality, perfectly stamped Copper terminals and excellent communication. Conex delivers exactly what our engineering drawings require.”

David R., UK – “Their technical understanding and ability to redesign my Copper connector helped reduce cost by 18%. Superb export packaging and zero rejections.”

FAQ (15 Technical Q&As)

1. What Copper grades are best for high-conductivity stamped parts?
ETP Copper C11000, Cu-ETP CW004A and OFC C10100 offer 100–101% IACS conductivity.

2. Can you produce stamping dies in-house?
Yes, our toolroom makes progressive, compound and single-stroke dies with EDM and CNC.

3. What thickness range can you stamp?
From 0.2 mm up to 8 mm depending on part geometry.

4. Do you offer Tin or Silver plating?
Yes, according to ASTM and EN plating standards for electrical contact performance.

5. Can you stamp Oxygen-Free Copper?
Yes, OFC Copper is commonly stamped for electronics and EMI-sensitive components.

6. Do you provide heat treatment or annealing?
Yes, continuous belt-type furnaces ensure uniform hardness control.

7. Can you export to USA and Europe?
We export globally with decades of compliance experience (RoHS, REACH).

8. Do you provide PPAP documentation?
Yes, PPAP Level 3, FMEA, control plans and inspection reports are available.

9. What is your MOQ for Copper stamped items?
Typically 5,000–10,000 pcs depending on part type and tooling.

10. Can you match customer-specific packaging?
Yes, we provide branded bags, labels, cartons and palletization.

11. Can you handle complex bending operations?
Yes, in-die bending and CNC forming allow multi-stage profiles.

12. What burr level can you control?
We maintain <0.05 mm burrs using deburring and brushing systems.

13. Do you support prototype development?
Yes, laser cutting or soft tooling is used for quick prototypes.

14. Do you offer dimensional inspection reports?
Yes, CMM and vision-system reports are provided per batch.

15. Can you supply Copper Stamped Terminals for EV applications?
Yes, including high-current terminals and battery connectors.

Material Properties (Reference Table)

Related Parts-

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Glossary of Terms

ETP Copper: High-conductivity Electrolytic Tough Pitch Copper used for stamped components.
Progressive Die: Multi-stage tooling used for fast, continuous stamping operations.
IACS: International Annealed Copper Standard for measuring conductivity.
Burr: Sharp edge left after stamping that must be removed.
Coining: High-pressure stamping for localized thickness control.
Annealing: Heat treatment to soften Copper before or after stamping.
OFC Copper: Oxygen-free Copper used in electronics and high-purity applications.

Call to Action

For custom drawings, samples, pricing or a detailed brochure, email us, request a quote or contact us on phone/WhatsApp. Our engineering team will guide you instantly.

Updated: 2025