Copper Stamping Parts Wholesale

Copper Stamping Parts

-- Steady & Reliable Manufacturer --

Yuyao Hongli Optoelectronics Co., Ltd. is a premier source manufacturer of Copper Stamping Parts, producing high-conductivity busbars, battery connectors, terminal lugs, and heat sink components for new energy electric vehicles (EV), power distribution systems, and electronics. Located in the Yangming Science and Technology Industrial Park of Yuyao, Zhejiang, our 5,000-square-meter facility features precision progressive presses, heavy-gauge hydraulic benders, and continuous tin/silver plating lines. We process C1100 (ETP Copper), C1020 (OFHC Copper), beryllium copper, and phosphor bronze into parts with high electrical and thermal conductivity. Count on Yuyao Hongli for custom busbar tooling, multi-layer insulation dipping, and high-volume OEM manufacturing.

MANUFACTURING CAPABILITIES

Equipment and process capabilities

From mold design to batch stamping, we cover production needs of different tonnages and precision levels.

  • 01

    Heavy-Gauge Busbar Stamping & Bending

    Utilizing high-tonnage precision presses and CNC hydraulic benders, we form thick C1100 copper bars into complex, multi-angle busbar shapes without cracking or edge distortion.

  • 02

    Precision Spring & Contact Stamping

    We process beryllium copper (C17200) and phosphor bronze (C5191) strips into intricate spring contacts, leaf springs, and micro-connectors with precise elastic recovery.

  • 03

    High-Speed Reel-to-Reel Stamping

    Our automated high-speed stamping lines produce mass quantities of copper terminals and clips on continuous reels, optimized for automated wire-harness assembly.

  • 04

    Insulation Powder Coating & Heat-Shrink Dipping

    We apply high-dielectric epoxy powder coatings and heat-shrink tubing to stamped copper busbars, ensuring safe electrical insulation in high-voltage EV battery packs.

SPEC · Overview of Key Equipment Parameters

Equipment TypeTonnage / SpecificationMachinable MaterialTypical Processing Thickness
High-Speed Precision Press25T - 110T High-Speed StampingC1100, C1020, C5191, C17200 Copper0.10mm - 2.0mm Copper Strip
Heavy Busbar Hydraulic Press80T - 250T Forming PressPure Electrolytic Tough Pitch Copper1.5mm - 8.0mm Heavy Busbar
Fluidized Bed Insulation Coating LineEpoxy Powder Dipping EquipmentStamped EV Copper Busbars0.5mm - 1.5mm Insulation Layer
Reel-to-Reel Electroplating LineContinuous Plating TanksStamped Copper TerminalsTin, Nickel, Silver Plating
QUALITY CONTROL

Full-process quality control system

From incoming material inspection to full outgoing inspection, key processes are equipped with inspection points to ensure batch consistency.

Electrical & Thermal Conductivity Verification

Ensuring maximum current-carrying capacity and low power loss across copper components.

  • Eddy current conductivity testing (verifying 鈮?100% IACS on C1100 pure copper).
  • Micro-ohmmeter contact resistance measuring across stamped joint interfaces.
  • Thermal imaging inspection during high-current load testing.

Dielectric Insulation & Voltage Breakdown Testing

Guaranteeing safety on insulated EV busbars and high-voltage power components.

  • Hi-Pot (High Potential) insulation breakdown testing up to 5000V DC.
  • Insulation layer thickness inspection using magnetic film gauges.
  • Adhesion testing of dielectric epoxy powder coatings per ISO 2409.

Plating Thickness & Bend Integrity Inspection

Confirming surface protection quality and freedom from material fracture along bend lines.

  • XRF measurement for tin, silver, and nickel electroplating thickness.
  • 180-degree bend radius crack inspection under 50x optical magnification.
  • 3D CMM coordinate checking for busbar mounting hole patterns.
SURFACE FINISHING

Surface treatment process

Depending on the usage environment and appearance requirements of the parts, we offer anti-corrosion, wear-resistant, or decorative surface treatment solutions.

Finishing ProcessApplicable MaterialPrimary FunctionTypical Application
Matte / Bright Tin PlatingC1100, C1020 Pure CopperPrevents copper oxidation, enhances solderability, and improves contact corrosion resistanceEV battery terminals, power distribution lugs, busbars
Silver ElectroplatingPure Copper, Beryllium CopperDelivers minimal electrical contact resistance for high-current transferHigh-voltage EV connectors, circuit breaker contacts, switchgear
Epoxy Powder Insulation CoatingHeavy Copper BusbarsProvides tough dielectric insulation against electrical arc-over and short circuitsEV battery pack interconnects, inverter busbars, energy storage racks
Nickel PlatingC5191 Phosphor Bronze, CopperActs as a barrier layer against zinc diffusion and increases surface wear resistanceSpring contacts, smart meter terminals, battery clips
Note: The above is a standard process list. Specific film thickness, color, and salt spray resistance rating can be customized according to customer drawings.
APPLICATIONS

Main application areas

Our products are widely used in industries that require high structural strength and precision consistency.

Electric Vehicle (EV) & Battery Pack Assemblies

High-purity copper busbars and connectors engineered for high-voltage battery modules.

  • EV battery cell interconnect busbars
  • High-voltage power distribution unit (PDU) copper bars
  • Inverter and drive motor copper terminal plates

Power Distribution & Renewable Energy

Heavy-duty stamped copper lugs and connectors for solar, wind, and grid power systems.

  • Solar inverter transformer copper connectors
  • Industrial circuit breaker busbars and switch clips
  • Power transformer grounding straps and lugs

Precision Electronics & Telecom Equipment

Intricate phosphor bronze and copper spring contacts for telecom and consumer devices.

  • 5G base station antenna spring contacts
  • PCB card edge connectors and shield clips
  • Smart meter current shunt copper plates
PRODUCTION / FACTORY ADVANTAGES

Factory production advantages

With its own factory and equipment, the company ensures stable delivery times and controllable costs.

20+ Years of Precision Copper Processing

Yuyao Hongli brings over two decades of specialized copper stamping, busbar fabrication, and contact spring manufacturing.

Integrated Stamping, Plating & Insulation

Our facility combines heavy busbar stamping, continuous plating, and epoxy insulation powder coating under one roof.

Strict Electrical Conductivity & Hi-Pot Testing

We perform 100% IACS conductivity checks and Hi-Pot insulation breakdown testing to guarantee zero electrical failures.

CUSTOM MANUFACTURING PROCESS

Customized production process

From receiving drawings to batch delivery, standardized processes ensure traceability at every stage.

  • 1. Electrical DFM & Material Specification Review

    Engineers evaluate ampacity, thermal dissipation, and bend radiuses to select the ideal copper alloy (C1100/C1020/C5191).

  • 2. High-Precision Die & Bending Tooling Build

    We design multi-station progressive stamping tools or CNC bending fixtures with polished inserts to prevent copper galling.

  • 3. Trial Stamping, Conductivity & FAI Audit

    Sample copper parts undergo IACS conductivity checking, CMM dimensional verification, and trial plating sign-off.

  • 4. Mass Stamping, Plating & Epoxy Coating

    Automated presses run high-volume stamping, followed by continuous tin/silver plating and dielectric epoxy coating.

  • 5. Hi-Pot Electrical Inspection & Packaging

    Finished copper busbars undergo 100% Hi-Pot voltage breakdown testing before being vacuum-sealed for shipment.

FAQ

Frequently Asked Questions

Here are some questions that clients often ask before cooperating with us.

What copper alloys do you process for stamping parts?

We work with C1100 (ETP Copper), C1020 (Oxygen-Free Copper), C5191/C5210 (Phosphor Bronze), and C17200 (Beryllium Copper).

Can you supply insulated copper busbars for EV battery packs?

Yes. We offer both fluidized-bed epoxy powder coating and heat-shrink PVC/PE insulation for high-voltage EV busbars.

What conductivity level do your pure copper stampings achieve?

Our C1100 and C1020 pure copper stampings achieve an electrical conductivity rating of 鈮?100% IACS.

Do you offer silver plating for high-current copper contacts?

Yes. We provide continuous reel-to-reel or rack silver plating to minimize contact resistance on high-current terminals.

About Us
Yuyao Hongli Optoelectronics Co., Ltd.
Yuyao Hongli Optoelectronics Co., Ltd.
Yuyao Hongli Optoelectronics Co., Ltd. is a comprehensive enterprise with over 20 years of experience in the manufacturing industry. Located in the Yangming Science and Technology Industrial Park of Yuyao, Zhejiang Province, it enjoys convenient transportation and a solid industrial foundation. As a famous China Copper Stamping Parts Suppliers and Copper Stamping Parts Factory, founded in 2000, formerly known as Yuyao Hongli Optoelectronics Educational Instruments Co., Ltd., the company is wholly owned by a natural person, with Xie Gang as the legal representative. Its registered capital of 500,000 yuan has been fully paid up, and it has maintained its continued development through stable operations.
Relying on a 5,000-square-meter modern factory and multiple stamping workshops, the company has built a diversified product system. Its core businesses cover the manufacturing, processing and wholesale and retail of educational instruments, optical instruments, household electric heaters, small household appliances, auto parts, hardware and plastic products, etc. At the same time, it operates and acts as an agent for the import and export trade of goods and technologies, and its products are sold at home and abroad.
The company brings together industry management elites and senior engineers to form a mature R&D and management team. Adhering to the business philosophy of "integrity and pragmatism," it is committed to providing customers with high-quality products and comprehensive after-sales service. Leveraging its diversified portfolio, certification guarantees, and import/export advantages, the company actively expands cooperation both domestically and internationally, and is willing to establish long-term and stable trade partnerships with partners from all sectors, continuously striving forward in the wave of intelligent and high-end development in the manufacturing industry.
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