Progressive Die Stamping for Copper Terminals

Copper Terminals Manufacturing Capability

The Process for Stamping Copper Terminals

1. Material Selection & Preparation

• Raw Material: Select a master coil of copper alloy (e.g., C2600 Brass or C5191 Phosphor Bronze) based on required conductivity and spring properties, typically 0.2–0.5 mm thickness.
• Pre-Plating (Optional): The coil may be pre-plated with nickel or tin before stamping.
• Loading: The coil is loaded onto a de-reeler and fed into the progressive die press.

2. The Stamping Process (Inside the Progressive Die)

The die has multiple stations. With each press stroke, the strip advances one station (pitch), and a specific operation is performed.

• Station 1 – Piercing (Pilot Holes): Small holes are punched along the carrier strip for accurate feeding and alignment.
• Station 2 – Notching & Trimming: The outer profile of the terminal is cut, defining the tongue and barrel width.
• Station 3 – Pilot & Forming: Pilot pins lock the strip; the tongue is coined or swaged to smooth edges.
• Station 4 – Barrel Forming (U-Shape): Wire barrel and insulation barrel are bent into a “U” shape.
• Station 5 – Barrel Closing (O-Shape): The “U” is curled further into a closed barrel around the future wire.
• Station 6 – Lance & Cut-off: The terminal is separated from the carrier strip, or kept on-strip for reel-form delivery.

3. Post-Stamping Operations

• Cleaning: Stamped strips pass through a chemical bath to remove stamping oil residue.
• Reeling: Finished strips are rewound onto reels for shipping and automatic crimping machines.

4. Quality Control (In-Process)

• Visual Inspection: Cameras check for missing material, deformation, or incomplete cuts.
• Dimensional Check: Micrometers and optical comparators verify length, width, and barrel diameter.
• Plating Thickness Test: X-ray fluorescence (XRF) verifies gold / tin / nickel plating thickness.

Why Progressive Die?

This method is chosen for high-volume production. It allows for:

• Speed: Thousands of parts per minute.
• Consistency: High precision and repeatability.
• Automation: Minimal human intervention required.
• Cost: Low cost per part once the tooling is made.

Typical Application Scenarios

• Electronic PCB Connections: Signal and power connection points on circuit boards.
• Automotive Electronics: ECUs, sensors, and harnesses requiring high reliability.
• Industrial Control: PLCs, motor controllers, and automation equipment.
• Consumer Electronics: Computers, home appliances, and internal wiring.
• Telecommunications: Routers, switches, and base station equipment.

Why they are suitable: Copper alloy ensures conductivity and elasticity; gold plating offers low contact resistance and corrosion resistance; crimp barrels enable secure, automated wire termination.

Our Process

• Inquiry: Customer sends drawings, specifications, material requirements, and estimated annual volume.
• DFM Analysis: We review part design for manufacturability and suggest cost-reduction improvements.
• Die Design: Engineers create progressive die layout, strip design, and station sequence using CAD software.
• Die Manufacturing: CNC machining, EDM, wire cutting, and precision grinding produce hardened tooling components.
• Sample Approval: First-article samples are stamped, inspected, and submitted for customer approval.
• Small Batch Order: Pilot runs validate die stability, tolerances, and plating quality before mass production.
• Mass Production: High-speed progressive presses run continuously with in-process inspection and SPC monitoring.
• Shipping: Finished terminals are reeled, packed, and delivered on schedule with full traceability documents.

Why Choose Us for Stamping Copper Terminals?

1. High-Conductivity Copper Materials

Our copper terminals are manufactured using high-quality copper materials such as C1100 oxygen-free copper, C2680 brass, and phosphor bronze. These materials offer excellent electrical conductivity, good formability, and strong resistance to oxidation, ensuring stable current transmission and long-term reliability.

2. Precision Progressive Die Stamping

We produce copper terminals through precision progressive die stamping, which allows high repeatability and tight dimensional control.

• Punches & Dies – Precision-ground to maintain accurate terminal geometry and consistent part quality.
• Pilot Pins & Stop Pins – Ensure accurate strip feeding and stable material alignment stroke after stroke.
• Guide Posts & Bushings – Maintain mold alignment and reduce wear during high-speed operation.
• Cutting & Forming Stations – Deliver clean edges, accurate bending angles, and reliable terminal shapes.

3. Strict Quality Control & Custom Manufacturing

We are an ISO-certified company with a strict quality control system. Every copper terminal is inspected for dimensions, surface quality, burrs, and forming accuracy to meet customer specifications.

4. One-Stop Copper Terminal Stamping Solutions

From mold design, progressive die manufacturing, material selection, stamping production, surface treatment, to final inspection, we provide one-stop stamping solutions. Our copper terminals combine high conductivity, stable performance, competitive pricing, and reliable quality.

We look forward to putting our stamping expertise to work for your copper terminal projects.