Progressive die stamping of copper busbars, terminals, contacts and heat sinks — dies designed and built in our own tool room, run on 21 presses from 25 to 110 tons at up to 300 SPM, held to ±0.005 mm on piloted features.
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PARTS WE STAMP
Copper gets specified where a part carries current or moves heat. These four families cover most of the copper metal stampings that run here, and each one carries its own die approach, plating route and inspection plan. Where a drawing arrives as a stamped copper part with no grade called out, we ask before we quote.
Blanked and formed busbars for inverter, rectifier and battery-pack builds — corner cuts, offset jogs and mounting slots in one progressive tool, so a finished bar leaves every stroke. We run C11000 and C12200 at the heavy end of our range; wide cross-sections need tonnage matched to shear area, not guessed.
Ring and spade terminals, lugs, contact bridges and battery posts from soft copper strip, typically 0.2–1.0 mm. Copper forms easily and marks just as easily, so the die faces that touch the contact side are polished and the lubricant is matched to whatever plating is on the strip.
Stamped copper fins and spreaders for set-top boxes, power supplies and LED drivers, where an extruded profile will not fit the enclosure. Copper takes the fin pattern from 0.6 mm up; because those faces are soft, parts are plated with protective media and packed to arrive scratch-free.
Grounding straps, shunts, stud assemblies and stamped copper laminations. Where the drawing calls for copper-to-copper joining, brazing and resistance welding are set up alongside stamping, and heavy-gauge slitting and blanking run on the larger presses in the fleet rather than forced onto a light frame.
INSIDE THE PLANT
Real equipment and inspection floor from our Dongguan plant — 25–110T high-speed presses, in-house tool room, and a CMM lab running first-article inspection on every program.
WHERE COPPER GOES WRONG
Copper is forgiving to draw and unforgiving to handle: it picks up on tool steel, moves after forming, oxides in days, and shears with a shock load at heavy gauge. These four failures get engineered out of custom copper stampings before the first production coil, and the same four decide what a copper stamping die is built from.
01
The Challenge
Copper is soft and chemically clean, so it picks up on bare tool steel and then tears. Pickup starts as a dull patch on a forming radius, grows into a scored part, and only shows on a dimension when the die already needs polishing — on heavy busbar stock that can happen inside one shift.
Our Solution
Forming inserts are hardened, polished and coated, and draw surfaces stay off bare steel. Lubricant is chosen for the plating on the strip instead of from habit, and stations are checked on a counted-stroke schedule, so pickup lands as a maintenance task rather than a surface reject at the customer.
02
The Challenge
Copper's springback is small, which is why it forms cleanly — but soft temper also means a formed busbar keeps moving in handling, packing and shipping. Bars that measured inside tolerance at the press arrive out of flat, and the assembly station ends up straightening parts before mounting.
Our Solution
Bend stations coin the radius instead of free-forming it, hold-down pressure is set per station, and gauge repeatability is checked across the coil rather than at one point. Parts are packed on edge, bend angle is verified on the CMM at first article and audited through the run.
03
The Challenge
At 2 to 3 mm, copper shears with a shock load and leaves a long burr if clearance is wrong. Slivers and rolled edges on a busbar become a short-circuit risk in service, and punching thick stock hard on a light press costs tool life and flatness at the same time.
Our Solution
Punch clearance is set per gauge, stepped or bevel entry lowers the shock load on heavy sections, and the press is matched to shear area with tonnage margin left over. Burr height is measured at first article and edges are deburred where the drawing allows it.
04
The Challenge
Bare copper oxides in days, and an oxide film on a joint face raises contact resistance and ruins solder wetting. Tin, silver and nickel each solve a different problem — tin for solderability and cost, silver for the lowest joint resistance, nickel as a wear barrier — and the wrong choice fails in the field, not at the press.
Our Solution
The plating route is decided at DFM from what the joint needs, not from the last program. Bare parts get anti-tarnish treatment and sealed packing; pre-plated strip runs on gentler die entry with no tumbling after forming. Film thickness and adhesion arrive with the mill certificate and are re-verified on incoming inspection.
HOW WE STAMP IT
These are the values we quote and inspect against on copper work: the gauge range the presses hold, the tolerance the CMM verifies, and nothing written for marketing.
| Specification Parameter | What We Hold | How It Is Controlled |
|---|---|---|
| Strip thickness | 0.05–3.0 mm | Coil certificate + in-process thickness check |
| Positional tolerance | ±0.005 mm on piloted features | First-article CMM at 0.001 mm resolution |
| Stamping speed | up to 300 SPM | High-speed frames for thin contacts, slower strokes on heavy busbar |
| Press fleet | 21 presses, 25–110 tons | Tonnage matched to the shear area of the part |
| Dies | 100% designed and built in-house | 30 machining machines behind the tool room |
| Quality system | IATF 16949:2016 · ISO 9001:2015 · ISO 14001:2015 | PPAP, mill certificates, lot traceability to the coil |
| Inspection | 20 inspection stations | CMM, optical and profile, in-line CCD on critical features |
| Surface and plating | tin, silver, nickel, selective gold | Qualified finishers, anti-tarnish on bare copper, incoming film and adhesion checks |
Progressive die design, machining and assembly under one roof. On copper that matters most at the forming stations, where pickup, bend compensation and edge condition are settled.
Thin copper contacts on the high-speed frames at up to 300 SPM; busbar and lamination stock from 1.5 to 3.0 mm on the larger presses, with tonnage margin for shear shock.
First-article CMM at 0.001 mm, optical and profile for edges and bend radii, in-line CCD vision on the features the drawing actually controls.
Tin, silver, nickel and selective gold through qualified finishers, with anti-tarnish on bare copper and film thickness plus adhesion verified on incoming inspection.
From Drawing to Production
Grade, temper, gauge, bend radii, burr side, tonnage and plating route settled before a die is cut — including whether the part belongs in copper at all.
Progressive layout with blanking, corner cuts, forming and coining combined; die machined, assembled and tried out in our own tool room.
Run on the production coil, bend angles and flatness checked on the CMM, PPAP documentation raised before the run is released.
Counted-stroke tool maintenance, in-line vision on critical features, SPC on the dimensions the drawing controls, lot traceability back to the coil.
STRIP AND SUPPLY
We stamp copper, we do not sell it. Tell us the joint, the current and the service environment, and the grade plus plating route are named before the die is cut. That is the same conversation behind custom copper stamped parts at any volume, from a prototype lot to a weekly release.
C11000 is the default conductor; C10200 and C10100 go where oxygen content or elevated temperature matters; C12200 where parts are brazed or welded; C19400 when a contact needs spring retention alongside conductivity. As an industry reference, annealed C11000 runs about 100% IACS.
Bare copper needs anti-tarnish treatment and sealed packing. Pre-tinned strip removes the post-plating step and protects the cut edge, at the cost of gentler die entry and no tumbling afterwards. Silver and selective gold go on the joint face only, decided at DFM.
Either you send coil to your own specification, or we procure the grade, temper, width and surface you name and quote material plus conversion with the mill certificate on file. Hardness and surface finish belong on the purchase order here, because soft copper shows every handling mark.
Grades we run
BEFORE YOU SEND THE DRAWING
Eight items worth settling on a copper drawing before tooling — the ones that decide whether the part runs cheap or fights the die for years.
INDUSTRY CASES
Oct 20 · 1 min read
A manufacturer of energy-storage and EV-charging cabinets came to us with a busbar problem: parts were cut and formed one operation at a time, so bend angles drifted…
Oct 20 · 1 min read
A set-top box OEM hit a thermal ceiling in a slimmer enclosure. Their extruded heat sink was being replaced with a stamped copper fin part, but the first supplier run…
Oct 20 · 1 min read
An automotive Tier-1 brought us an L-shaped contact that cost more than the assembly it went into. The design welded a separately gold-plated contact button onto a…
ORDERING & FAQ
From drawing to delivered parts: a four-step path with engineering review at the front and 100% dimensional inspection at the back — then the questions buyers ask us most.
Step 1
Submit CAD & Specs
Send 2D/3D drawings (STEP, DWG, PDF) with quantity, material, and tolerance requirements.
Step 2
DFM Feedback & Quotation
Our engineering team conducts DFM analysis and follows up with a competitive quote after the review.
Step 3
Precision Manufacturing
High-speed progressive die stamping, secondary forming, finishing, and surface treatment per your specifications.
Step 4
100% QC & Express Shipping
100% dimensional inspection, anti-corrosion packaging, and global express delivery.
Either. We are a stamper, not a metal distributor, so we do not sell copper. You can supply coil to your own specification, or we procure the grade, temper, width and surface you name and quote material plus conversion.
C11000 and C10200 are the workhorses, with C10100 for oxygen-free duty, C12200 where parts are brazed or welded, and C19400 when a contact needs spring retention on top of conductivity.
0.05 mm at the thin end and 3.0 mm at the heavy end. Thin copper contacts and shields run on the high-speed presses; busbar and lamination stock runs on the larger presses in the fleet.
Yes. Pre-tinned strip removes the post-plating step and protects the cut edge, provided the die is built for gentler entry and the parts are not tumbled. Conflicting plating call-outs get flagged at DFM.
±0.005 mm on piloted positional features, verified on a CMM at first article. Formed dimensions depend on bend count, radius and temper, so the critical ones are agreed at DFM and controlled with SPC.
Copper carries the same current in roughly 60% of the cross-section and holds a clamped joint without cold flow, so it wins on space and joint reliability. Aluminum wins on weight and cost where the larger section fits.
Yes. Prototype copper stamping starts from soft tooling or laser-cut blanks formed on a brake — enough to prove the joint, the bend and the plating route. Once volume is confirmed, stamped copper parts move onto a progressive die, and 2 to 3 mm work moves to the larger presses.
Copper progressive stamping pays where a bar needs several stations: corner cuts, an offset jog and mounting slots in one pass, so the bar leaves every stroke finished. On a single-bend strap at low volume a compound die is cheaper and we quote it that way.
Yes, and it is usually the right answer where the part has to hold spring force: beryllium copper stampings in C17200 carry a fraction of pure copper's conductivity but several times its strength, and they are aged after forming. Pure copper stays the call where conductivity is the whole job.
Ready to Start Your Precision Stamping Program?
Send your drawing today — engineering runs a free DFM review and detailed pricing follows the review.
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