Copper Impact Extruded Parts – Impact Extrusion Copper Components
A1 Metallics specializes in the manufacture and export of Copper Impact Extruded Parts and components. Impact extrusion is a cold-forming process in which a copper slug is struck by a punch at high velocity and pressure, causing the metal to flow around the punch or through a die orifice to form hollow or complex solid shapes in a single stroke. This process delivers exceptional dimensional consistency, superior surface finish, and excellent mechanical properties.
Copper’s outstanding malleability and ductility make it one of the best materials for impact extrusion, enabling the manufacture of thin-walled, complex geometries at high production rates with minimal material waste – making it highly cost-effective for medium to high volume production.
What is Copper Impact Extrusion?
In impact extrusion of copper, a pre-cut copper slug (disc or rod section) is placed in a die and struck by a punch under high-speed hydraulic or mechanical press force. The copper deforms plastically, flowing in one of two ways:
- Forward (Direct) Extrusion: Copper flows in the same direction as punch movement – for solid rods, pins, and stepped profiles
- Backward (Indirect) Extrusion: Copper flows backward around the punch – for cups, tubes, and hollow shells
- Combined Extrusion: Combination of forward and backward flow for complex shapes
Also known as: Copper Cold Extrusion | Copper Slug Extrusion | Copper Cold Impact Pressing | Copper Cold Formed Parts | Copper Backward Extrusion | Copper Forward Extrusion | Copper Press Parts | Copper Impact Formed Components
Types of Copper Impact Extruded Components
- Copper Tubes & Shells – Thin-walled hollow copper cylinders for electrical contacts, connectors, and enclosures
- Copper Cups & Caps – Closed-end copper shells for terminals, capacitor cans, and switchgear parts
- Copper Connector Bodies – Complex hollow shapes for multi-pin connector inserts
- Copper Contact Sleeves – Precision sleeves for crimp and splice connectors
- Copper Terminal Shells – Hollow terminal bodies for electrical connectors
- Copper Tube Ends & Ferrules – End caps and ferrules for cable terminations
- Custom Impact Extruded Parts – Any hollow or stepped shape per customer drawing
Related Terms
Copper Cold Extruded Parts | Copper Impact Formed Parts | Copper Slug Formed Components | Copper Backward Extruded Parts | Copper Cold Pressed Parts | Copper Hollow Components | Copper Extruded Cups | Copper Extruded Shells | Copper Impact Pressed Parts | Cold Extrusion Copper | Copper Forward Extrusion Parts | Copper Thin-Wall Components
Copper Grades & International Equivalents
| Grade | US (UNS) | European (EN) | Indian (IS) | British (BS) | Extrusion Suitability |
|---|---|---|---|---|---|
| ETP Copper (C11000) | UNS C11000 / ASTM B187 | CW004A (Cu-ETP) | IS 191 ETP | BS C101 | Excellent – most widely used for copper extrusion |
| Oxygen-Free Copper (C10200) | UNS C10200 | CW008A (Cu-OF) | IS 191 OF | BS C103 | Excellent – highest purity, for electronic components |
| DHP Copper (C12200) | UNS C12200 | CW024A (Cu-DHP) | IS 191 DHP | BS C106 | Good – phosphorus deoxidized, weldable grade |
| Tellurium Copper (C14500) | UNS C14500 | CW118C (CuTeP) | — | BS C109 | Good – free-machining, for precision extruded pins |
| Beryllium Copper (C17200) | UNS C17200 | CW101C (CuBe2) | — | — | Moderate – for high-strength spring contact applications |
Manufacturing Specifications
- Press Capacity: 50T – 500T mechanical and hydraulic impact presses
- Slug Weight: 5g – 2kg per piece
- Wall Thickness: 0.3mm minimum (depending on alloy and geometry)
- Diameter Range: 5mm – 150mm
- Length Range: 5mm – 400mm
- Tolerances: ±0.05mm (extruded), ±0.01mm (machined after extrusion)
- Surface Finish: Bright, Tinned, Nickel Plated, Silver Plated, Annealed
Advantages of Copper Impact Extrusion
- Near-net-shape manufacturing – minimal material waste
- Excellent dimensional consistency for high-volume runs
- Superior surface finish directly from the die
- Work-hardened structure improves mechanical strength
- Thin walls achievable not possible by machining
- High production rates – millions of pieces per month
- Cost-competitive for medium to high volume applications
Applications
- Electrical connector bodies and housings
- Crimp connector sleeves and ferrules
- Capacitor cans and battery cell contacts
- Automotive electrical contact bodies (EV connectors)
- RF/coaxial connector bodies
- PCB standoffs and hollow spacers
- Relay and solenoid cores
- Aerospace connector shells
Why Choose A1 Metallics?
- ✅ Dedicated Impact Extrusion Lines – Specialized cold extrusion presses for copper components
- ✅ ISO 9001:2015 Certified – Quality management at every step
- ✅ In-house Tooling & Die Making – Rapid die development for new parts
- ✅ Integrated Finishing – Post-extrusion machining, annealing, plating all in-house
- ✅ High Volume Capability – Millions of pieces per month for mass production
- ✅ 25+ Years Manufacturing Experience – Reliable partner for global connector OEMs
- ✅ Export Expertise – Supplying to 40+ countries including USA, UK, Germany, Canada
Request a Quote
Looking for Copper Impact Extruded Parts for your connector or electrical assembly? Send your drawing, sample, or specification to A1 Metallics for a competitive quote.
📧 sales@a1metallics.com | 📞 +91-22-43449300/27
