Why Manufacturers Are Ditching Aluminum
Over 40% of electrical failures stem from inferior connectors (2024 IEEE Report)[1]. Copper stamped parts solve this with unmatched conductivity. Our team’s 2025 EV battery project achieved 99.98% efficiency using micro-stamped copper terminals – a 15% improvement over aluminum rivals.
Material Showdown: Copper vs Aluminum Stamping
|
Copper |
Aluminum |
| Conductivity |
100% IACS |
61% IACS |
| Tool Wear |
500k cycles |
200k cycles |
| Recyclability |
Infinite |
5-7 cycles |
7-Step Production Protocol
- Select C11000 electrolytic copper (≥99.9% purity)
- Design progressive dies with ≤5μm tolerance
- Apply Teflon coating to blanking surfaces
- Set press speed at 120-150 SPM
- Implement inline laser thickness monitoring
⚠ Never anneal mid-run without recalculating springback – copper’s work hardening ratio changes dramatically!
Quality Control Checklist
- ▢ Verify grain direction matches CAD models
- ▢ Test edge burrs with 10x magnification
- ▢ Measure conductivity post-stamping
