Copper & Brass Parts Manufacturing

Precision CNC machining, sheet metal fabrication, and busbar bending for Pure Copper and Brass components. Delivering high conductivity, excellent wear resistance, and tight tolerances down to ±0.01 mm.

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Popular Copper Alloys & Specifications

Select the ideal copper or brass grade tailored to your manufacturing process, electrical conductivity, thermal requirements, and surface finishing needs.

Alloy Grade	Primary Process	Key Characteristics & Advantages	Typical Applications
Pure Copper C11000 ETP High Conductivity	CNC Machining Sheet Metal	100% IACS high electrical and thermal conductivity. Superior ductility, natural corrosion resistance, and high malleability for heavy power transmission.	EV battery busbars, power distribution, electrical contacts, heat sinks.
Brass C36000 Free-Machining Standard	CNC Machining	Industry benchmark for machinability (100% rating). Delivers excellent surface finish, tight threaded tolerances, high strength, and low tool wear.	Precision threaded fasteners, fluid valves, gears, electrical pin connectors.
Oxygen-Free Copper C10200 OFC Ultra-Pure Grade	CNC Machining Sheet Metal	High-purity oxygen-free copper (99.95% Cu) with high thermal conductivity and resistance to hydrogen embrittlement under vacuum brazing.	Semiconductor equipment, vacuum electronics, high-end audio, particle physics components.
Brass C26800 / C26000 Stamping & Bending Brass	Sheet Metal	Non-leaded yellow brass with exceptional cold-working capacity, deep-drawing ductility, and an attractive golden metallic appearance.	Stamped terminal connectors, radiator cores, electrical clips, architectural trim.
Beryllium Copper C17200 Ultra High-Strength & Spring	CNC Machining	Combines high tensile strength comparable to alloy steel with high hardness, non-sparking properties, and outstanding spring fatigue resistance.	Spring contacts, non-sparking safety tools, aerospace bushings, injection molds.
CuCr1Zr (Copper Alloy) Additive Manufacturing	3D Printing (SLM)	Copper-Chromium-Zirconium powder optimized for metal 3D printing. Combines high thermal conductivity with superior mechanical strength.	Rocket engine nozzles, conformal cooling channels, induction coils, organic heat sinks.

Mechanical & Physical Property Comparison

Property	C11000 (Pure Copper)	C36000 (Free Brass)	C17200 (Beryllium Cu)	CuCr1Zr (3D Print Cu)
Tensile Strength	220–380 MPa	380–550 MPa	1100–1400 MPa	350–500 MPa
Yield Strength	70–300 MPa	150–310 MPa	900–1200 MPa	250–400 MPa
Hardness (Brinell)	50–90 HB	110–160 HB	350–400 HB	110–130 HB
Electrical Conductivity	100% IACS	28% IACS	20–25% IACS	75–85% IACS
Density	8.89 g/cm³	8.50 g/cm³	8.25 g/cm³	8.90 g/cm³
Machinability Rating	Fair (20%)	Excellent (100%)	Good (50%)	Good (Post-CNC)

Surface Finishes for Copper & Brass

We offer a wide range of custom surface finishing options for copper and brass parts as part of our manufacturing services. Each finishing process is precisely executed to prevent oxidation, enhance electrical conductivity, improve wear resistance, and deliver an aesthetic metallic appearance.

As-Machined

Copper and brass parts are left directly as machined with natural metallic luster. Preserves tight dimensional tolerances for precision press-fit contacts, with surface roughness ranging from Ra 0.8 to 3.2 µm.

Electroplating (Tin, Silver, Nickel, Gold)

Deposits a thin protective metal layer via electrolysis. Silver and tin plating enhance electrical conductivity and solderability for EV busbars, while nickel plating improves hardness and corrosion resistance.

Passivation & Anti-Tarnish

A specialized chemical immersion process that forms a transparent, microscopic protective barrier on copper/brass surfaces. Prevents tarnish, patina, and fingerprint stains without altering part dimensions.

Polishing & Brightening

Mechanical or electrochemical polishing removes tool marks and micro-burrs, producing a mirror-like, highly reflective golden or reddish luster. Ideal for decorative hardware and luxury consumer products.

Black Oxide & Antique Finishing

Chemical conversion coating that produces a uniform black or aged antique brass/copper patina. Commonly used for optical housings, decorative hardware, architectural fittings, and low-reflectivity components.

Bead Blasting

Uses fine glass beads under high pressure to clean copper surfaces and eliminate cutter lines, producing a smooth, non-reflective matte satin texture for a consistent aesthetic finish.

Clear Lacquer / Powder Coating

Applies a clear protective lacquer or electrostatic powder coat over raw/polished copper and brass. Locks in bright metallic color and provides long-term resistance against UV, air oxidation, and wear.

Chromate Conversion Coating

Provides mild atmospheric corrosion resistance while maintaining low electrical contact resistance across copper joints, grounding straps, and precision electronic enclosures.

Advantages and Considerations of Copper & Brass Machining

Copper and brass alloys are widely specified across electronics, automotive, and fluid control industries due to their exceptional physical properties. Understanding their key performance advantages and machining characteristics helps in selecting the ideal alloy grade for your engineering requirements.

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Advantages of Copper & Brass

Unmatched Electrical & Thermal Conductivity: Pure copper provides supreme electrical (100% IACS) and thermal conductivity, making it the industry standard for EV battery busbars, connectors, and heat sinks.
Outstanding Machinability (Brass Alloys): Free-cutting brass (e.g., C36000) offers 100% machinability rating, enabling ultra-fast CNC turning, excellent surface finishes, and tight threaded tolerances.
Superior Corrosion & Biofouling Resistance: Naturally resists corrosion from water, moisture, and mild chemicals, while inherently inhibiting bacterial growth due to its natural antimicrobial properties.
Excellent Ductility & Cold Formability: Pure copper and yellow brass exhibit exceptional ductility, ideal for complex sheet metal stamping, deep drawing, and precision busbar bending without cracking.
Aesthetic Value & Premium Finish: Offers natural rich metallic colors (reddish copper & golden brass) that accept mirror polishing, antique patinas, and electroplating for decorative applications.

Considerations & Limitations

Gummy Cutting Behavior (Pure Copper): Unalloyed copper is soft and ductile, making it prone to burr formation during milling. *(Solution: Optimized tool geometry or choosing free-machining brass for non-conductive structural parts)*.
Higher Raw Material Cost: Copper is significantly more expensive than aluminum and carbon steel per kilogram due to global commodity pricing and refining processes.
Susceptibility to Rapid Surface Oxidation: Bare copper and brass form a dark oxide patina over time when exposed to air and humidity. *(Solution: Anti-tarnish passivation or tin/nickel electroplating)*.
Higher Weight & Density: With a density of ~8.9 g/cm³, copper is nearly three times heavier than aluminum, requiring weight considerations in aerospace or portable devices.

Copper & Brass Machining FAQs

1. What is the main difference between Pure Copper and Brass for custom manufacturing?

Pure Copper (e.g., C11000, C10200): Consists of 99.9%+ copper with reddish appearance. It delivers maximum electrical (100% IACS) and thermal conductivity, making it ideal for EV busbars, power contacts, and heat sinks.
Brass (e.g., C36000, C26800): An alloy of copper and zinc with a golden appearance. It features superior machinability (100% rating), higher hardness, and lower cost, making it perfect for threaded valves, fittings, fasteners, and gears.

2. Why is tin, nickel, or silver plating recommended for custom copper components?

Bare copper and brass oxidize rapidly in air, forming a dark patina. Electroplating adds a protective barrier:

Tin Plating: Prevents oxidation and provides excellent solderability for EV battery busbars.
Nickel Plating: Offers high hardness, wear resistance, and long-term corrosion protection.
Silver Plating: Delivers maximum electrical conductivity and low contact resistance for high-voltage power transmission.

3. Can you manufacture custom copper busbars with insulation tubing or coating?

Yes. We offer end-to-end custom copper busbar fabrication, including CNC punching, laser cutting, precision hydraulic bending, surface electroplating (tin/nickel/silver), and the application of heat-shrinkable PVC/PE insulation sleeves or fluid bed epoxy powder coating for high-voltage dielectric safety.

4. How do you control burrs and deformation when machining soft pure copper?

Pure copper is highly ductile and prone to tool clogging. We utilize custom high-rake sharp carbide cutting tools, high-pressure coolant systems, optimized high-speed milling feeds, and specialized clamping fixtures to prevent part distortion and achieve burr-free, tight-tolerance (down to ±0.01 mm) finished components.

5. What file formats are required for an instant copper parts quote and production?

For automated 3D pricing and DFM (Design for Manufacturability) evaluation, please submit 3D CAD files in STEP (.stp / .step), IGES (.igs), or SolidWorks (.sldprt) format. For custom screw threads, tight tolerances, or critical surface plating specifications, please also include a 2D drawing in PDF or DWG format.