Copper stampings 0.2 - 3 mm

When manufacturing busbars from Cu-ETP, we achieve positional tolerances of ±0.05 mm through precision stamping to ensure an accurate fit in the tight installation spaces of battery technology. Mechanically, exceeding this window leads to stresses in the housing integration, which reduces the vibration resistance of the overall system. In contrast to standard stamped parts, compliance with ISO 2768-f (fine) is the technical limit here in order to rule out assembly errors in automated lines.

With increasing material thickness in the range of 0.2 to 3 mm, the risk of pronounced burr formation increases, as the cutting gap grows in proportion to the thickness and the ductile copper tends to flow. Mechanically, an uncontrolled burr can puncture the insulation foils of battery modules, leading to life-threatening short circuits. Karl Naumann GmbH minimizes this risk by regularly regrinding the tools in order to deliver copper stampings with a defined burr of less than 0.05 mm.

For copper stampings with high conductivity, we primarily use Cu-ETP (CW004A) in accordance with DIN EN 13601, as the oxygen content optimizes the electrical conductivity to at least 57 MS/m. Chemically and physically, this ensures low-loss energy transport in inverters, while alloys such as Cu-DHP are more suitable for welding applications due to their deoxidation, but are electrically less efficient. A conductivity below 56 MS/m is an exclusion criterion for high-current applications, as this leads to thermal overload.

A critical no-go error is insufficient edge rounding on components that are subsequently electrolytically coated, as the so-called "tip effect" leads to uneven layer thicknesses. Electrically, this results in a local increase in contact resistance, which leads to unacceptable heating in copper stamped parts for e-mobility. We therefore use mass finishing to create a homogeneous surface base for subsequent silver plating.

Inadequate edge quality with chipping or flake formation is not suitable for automated feeding processes with copper sheet metal stamped parts, as metallic residues interfere with the sensors of the pick-and-place machines. Mechanically, these particles lead to leakage currents in the power electronics. Copper stamped parts with defined edge quality are therefore absolutely essential in order to validate process reliability in large-scale production.

The forming process for stamped and bent parts increases the dislocation density in the copper structure, which increases the hardness and drastically reduces the ductility. Mechanically, excessive work hardening in multiple bent parts leads to the formation of cracks in the outer radius, which destroys the mechanical load-bearing capacity of the copper stamped-bent parts. We limit this effect by selecting the correct initial condition (e.g. R240) and optimized bending radii to prevent component breakage.

For copper stamped parts with tight tolerances, we primarily use optical 3D inspection to detect contour deviations without contact or distortion. In contrast to tactile measurement, this prevents plastic deformation of the soft copper fine blanking parts during the measurement process. A calibrated measurement report is a prerequisite for proving the conformity of the copper stamped parts with hole pattern to the OEM.

The copper stamped parts with initial sample test report (EMPB) documents the complete conformity of the first series tools with the customer specification under real production conditions. This process validates the entire process chain and ensures that all dimensions are within the drawing specifications. Without this approval, there is a risk of series errors, which can lead to costly recalls in the automotive industry.

When specifying copper stampings for electrical contacts, the copper stampings must be designed with a defined surface roughness (e.g. Rz less than 6.3) to reduce contact resistance. Electrically, a surface that is too rough increases the micro-bottlenecks in the current flow, which increases the power loss. We recommend an additional surface treatment such as tinning to permanently prevent the copper from oxidizing.

For copper stampings for busbars in industrial switchgear, we manufacture components from Cu-ETP with tolerances of ±0.1 mm for thicknesses of up to 3 mm. Mechanically, this is crucial for precise housing integration in modular power distribution systems, where cumulative tolerances would otherwise prevent the main busbars from being installed. We use progressive die stamping to ensure consistent dimensional accuracy even with copper stampings in large series.

Belt punching enables high stroke rates and automated feeding as the raw material is continuously fed through the tool. Mechanically, this results in a high repeat accuracy of the copper stamped parts for power distribution systems, as the positioning is fixed in the tool via pilots. In contrast to insert punching, the risk of punching errors is massively reduced, which increases the availability of components for the electrical industry.

Copper stampings for EMC concepts often require complex contours and multiple openings to act as shielding or earthing points. Electrically, copper offers the best shielding attenuation against high-frequency interference signals due to its high conductivity. A technical exclusion criterion here is insufficient flatness, as the smallest gaps nullify the EMC protective effect due to leakage radiation.

A no-go error with stamped sheet copper parts is the contamination of the surface with foreign particles (e.g. steel chips) during the stamping process, which leads to localized corrosion. Chemically, copper forms galvanic elements with less noble metals in a moist environment, which jeopardizes the long-term stability of the contact points. Karl Naumann GmbH uses separate tool sets to consistently avoid this cross-contamination of copper stamped parts.

The controlled edge zone ensures that the residual stresses induced by the cut do not reduce the electrical conductivity locally due to grid defects. Mechanically, an excessively disturbed edge zone in copper stampings for switchgear could lead to microcracks under alternating thermal stress. Failure due to crack propagation in the main power connection would be a catastrophic failure scenario for power distribution.

When punching copper sheet in accordance with DIN EN 1652, a pressure forming zone is created at the cut edge, which causes a local increase in hardness. Mechanically, this reduces the deformation reserve for subsequent process steps such as collar drawing. We monitor these edge zone changes to ensure that the copper stamped parts for component assembly do not have any brittle areas that could break during screw fastening.

A lack of process capability leads to fluctuations in the hole position, which distributes the contact force of the screw connection asymmetrically in copper stampings for contact and earth connections. Mechanically, this results in uneven contact pressure, which leads to electrical hotspots. We validate the copper stamped parts with a validated process chain in order to guarantee compliance with the strict quality standards in energy technology.

Calibrated gauges and optical measuring systems are absolutely essential for copper stamped parts according to drawings in order to verify features such as edge rounding. Without these testing and measuring devices, critical parameters such as the roughness of the functional surfaces cannot be objectively evaluated. A lack of measurement reference means that precision stamped parts made of copper cannot be approved for safety-critical network applications.

Copper stampings with traceability are essential in order to be able to identify all affected components in the supply chain in the event of a batch defect in the base material (e.g. inclusions). We document the coil numbers and melting data for each batch of copper stampings for energy technology. A lack of documentation is an exclusion criterion for projects in the critical infrastructure sector.

A surface treatment such as nickel or silver plating protects the copper from oxidation and permanently reduces the contact resistance. Chemically, the coating prevents the formation of poorly conductive copper oxide in thermally stressed assemblies. Karl Naumann GmbH recommends electroplating for copper stampings for electrical contacts in order to ensure corrosion resistance and electrical performance over the entire service life.

Earthing lugs are manufactured as copper stampings for electrical contacts in order to securely connect housing parts to the protective conductor. Mechanically, these components made of Cu-ETP must have high corrosion resistance and mechanical strength. Failure of the connection due to corrosion cancels the electrical protection, which is life-threatening for the user.

Work hardening increases the yield strength of the copper locally, which is used for copper stamped and bent parts in fastening technology in order to achieve higher clamping forces. Mechanically, however, the hardening must not lead to the material breaking brittle under load. We calculate the degree of deformation precisely in order to supply copper stamped parts with high repeat accuracy and optimum strength.

In terminal blocks, a deviation in the copper stamped parts with reproducible hole position means that the clamping screws do not meet the copper centrally. Mechanically, this results in insufficient torque and electrically in excessive contact resistance. We ensure the hole spacing by fine blanking to guarantee error-free assembly in the electrical industry.

In railroad technology, copper stamped parts for busbars are used as flexible connectors between battery modules or in switch cabinet construction. Mechanically, these components must be able to withstand extreme vibrations without fatigue fractures occurring. A no-go fault here is an uncontrolled edge zone with sharp notches that act as a crack initiator.

Surface treatment with tin plating protects the copper from oxidation and greatly improves wettability during soldering. Chemically, the tin forms an intermetallic phase with the copper, which ensures a permanent bond. Copper stamped parts with surface treatment are therefore technically without alternative for automated PCB assembly.

Copper stamped parts for automated feeding must have a high degree of dimensional stability in order to avoid getting caught in vibratory bowl feeders. Mechanically, complex geometries limit the feeding speed if the parts tend to interlock. We optimize the design of copper stamped parts for assemblies to enable trouble-free automation.

In metrology, copper stampings with reference edges are used as a zero point for calibrating test equipment. Mechanically, precision stamping ensures that these edges are absolutely straight and square. A deviation at the reference edge leads to systematic measurement errors, which devalues the quality of the entire testing and measuring equipment.

Copper stampings for power electronics used in inverters require a copper stamping with a test certificate that confirms the electrical conductivity and dimensional accuracy of the contact surfaces. Without this certificate, the thermal stability of the electronics cannot be guaranteed. Karl Naumann GmbH supplies this documentation as part of the validated process chain.

An uncontrolled burr on copper stamped parts can lead to electric flashovers if the clearance and creepage distances between two conductors are undershot. Electrically, the burr acts as a field strength peak that promotes ionization. We guarantee copper stampings with deburred edges to ensure high-voltage safety in energy technology.

The copper stamped parts with initial sample test report gives the technical purchasing department the assurance that the copper stamped parts ordered meet all technical specifications and have been approved for series production. It is the central document for minimizing risk when selecting suppliers. A missing EMPB is a formal exclusion criterion for quality-critical assemblies.

In electrified office furniture or kitchen systems, copper stampings are used for electrical contacts in the form of slide switches or connectors. Mechanically, these copper stampings in small series must have a high spring force and fatigue resistance. A reduction in contact force leads to arcing and therefore poses a significant fire risk.

Inadequate edge rounding on copper stamped and bent parts can lead to cuts or damage cable insulation during installation or use. Mechanically, sharp edges reduce the impact energy of the component. We use brushing or vibratory grinding to deliver copper stampings with deburred edges that meet the safety standards for end-user products.

Copper stampings with surface treatment such as brushing and subsequent clear coating are often used for visible design elements or handles. Chemically, the coating prevents the copper from tarnishing due to hand perspiration. A technical exclusion criterion for visible parts are scratches or drawing marks from the copper sheet metal stamping process, which impair the appearance.

A no-go error with copper punched parts with a hole pattern is a center offset of the holes, which is caused by unstable strip guidance in the strip punching. Mechanically, the fastening screws do not fit through the punched copper sheet metal parts, which drastically reduces the assembly speed. We guarantee copper stamped parts with high repeat accuracy thanks to precise tool guides.

In moving joints, a brittle edge zone leads to premature wear due to abrasion of the hardened layers. Mechanically, the controlled edge zone acts as a plain bearing support that minimizes friction. Karl Naumann GmbH optimizes the cutting parameters to create an edge zone that maximizes the service life of the joint fittings.

In smart home furniture, copper stamped parts for component assembly are used as conductor tracks or antenna structures. Electrically, these components must enable loss-free signal transmission for WLAN or Bluetooth modules. Oxidation of the contact surfaces is a technical risk, which is why we often tin plate copper stampings with high conductivity.

The copper stamped parts with sampling inspection plan ensures that the quality specifications are statistically verified, even for large quantities for the furniture industry. We test characteristics such as dimensional accuracy and surface quality in accordance with the AQL standard. Inadequate testing leads to high complaint rates in the furniture trade.

For copper stampings with complex contours, the yield point of the material sets the limit for very delicate structures that could bend under mechanical load. We advise designers on choosing the right sheet thickness between 0.2 and 3 mm to ensure the stability of precision stamped copper parts. A design that is too thin will lead to permanent deformation during use.

Copper stamped parts according to drawings allow the realization of specific technical functions that cannot be covered with standard parts. Mechanically, we manufacture exactly according to the customer's CAD data to enable seamless integration into the furniture structure. Deviations from the drawing lead to unstable connections and are a criterion for exclusion.

Grinding or polishing enhances the feel of the stamped copper parts, which is crucial for control elements in the premium furniture sector. All sharp transitions are mechanically removed. Karl Naumann GmbH offers copper stampings with edge processing that meet the highest standards of ergonomics and aesthetics.

The copper fineblanking process enables an extremely smooth cut surface without the usual indentation zones of conventional stamped parts. Mechanically, this results in a higher accuracy of fit for precision mechanical axles. This is crucial in the watch industry, as rough edges increase friction and drastically reduce the power reserve of the watch.

Even microscopic residues of punching oils can resinify in movements and block the mechanics. The copper stampings according to drawing are therefore cleaned in special ultrasonic baths and packaged under clean room conditions. Contaminated copper stampings lead to expensive reworking and warranty claims by the end customer.

The copper stamped parts for optical 2D inspection allow complex contours to be checked in a cycle of seconds, which is economically necessary for copper stamped parts in large-scale production. The smallest deformations on spring contacts can be detected mechanically, which could not be detected tactilely. Failure of this control leads to functional errors in the final assembly of the watches.

Silver plating is necessary to ensure the contact reliability of the smallest switches over decades. The silver chemically prevents the formation of insulating oxide layers on the copper fine blanking parts. Without this surface treatment, the electrical resistance would increase, which would lead to functional failure at the low voltages in quartz watches.

A critical defect is a flatness error in the copper stamped parts with complex contours, which is caused by uneven residual stresses during stamping. These parts then grind mechanically on adjacent wheels or bridges in the movement. Karl Naumann GmbH uses special straightening processes to supply stamped sheet copper parts with maximum flatness.

Work hardening makes the subsequent engraving or polishing of copper housing inlays more difficult. Mechanically, tool wear increases massively during post-processing. We control the copper stamped parts with a controlled edge zone so that an optimum balance between component hardness and machinability is achieved in order to avoid rejects in final production.

For luxury watches, the copper stamped parts with documented traceability are part of the quality promise to guarantee the purity of the alloys used. We fully document conformity in accordance with DIN EN 1652. The use of inferior copper alloys would damage the brand image and jeopardize the long-term stability of the watches.

In watch laboratories, copper stamped parts are used for testing and measuring devices as highly conductive test contacts for measuring the current consumption of quartz movements. Electrically, these parts must have a minimum inherent resistance in order not to falsify the measurement results. We manufacture these precision stamped parts from copper with specially rounded edges so as not to damage the sensitive prototypes.