Custom T2 Copper Busbar Components

Key Technical Highlights: Busbars—say, 3 to 5mm thick—need high punching force, which can easily cause the mold to chip or the workpiece to warp. When bending them, stress tends to concentrate and cause cracking, so we need to design a little big bend radius and make sure we have done proper annealing before punching. Hole positioning has to be super precise too; we always make the mold part by slow wire cutting to control the mold clearance (normally we set it at about 4% to 9% of the material thickness). Thick copper plates tend to warp—especially larger parts—and the hole positions and overall dimensions can drift quite a bit, so usually we do a leveling process after stamping, or make another fine stamping to keep accuracy within ±0.02mm.