Brass & Copper Parts is a specialized manufacturer of precision copper sheet metal parts and copper sheet metal components, serving OEMs, electrical manufacturers, and contract manufacturers across the USA. We combine advanced stamping, CNC punching, laser cutting, bending, and forming technologies with deep expertise in copper alloy processing to deliver high-quality copper sheet metal components that meet exact specifications, dimensional tolerances, and surface finish requirements.
What Are Copper Sheet Metal Parts?
Copper sheet metal parts are components manufactured from flat copper sheet or strip stock through processes including blanking, stamping, punching, piercing, bending, forming, drawing, and laser cutting. Unlike machined parts (produced from bar stock), sheet metal parts are produced with minimal material waste and are ideal for flat, thin-walled, or complex 2D and 3D profiles that would be expensive or impractical to machine from solid.
Copper sheet metal components are used extensively in the electrical and electronics industries for their unmatched electrical conductivity, excellent thermal properties, superior corrosion resistance, and ease of soldering, brazing, and welding. They are also found in HVAC, architectural, and decorative applications where copper’s appearance and weather resistance are valued.
Our Range of Copper Sheet Metal Parts & Components
We manufacture a full spectrum of copper sheet metal components across various production processes:
Copper Stamped Parts & Blanked Components
High-volume copper stampings produced from progressive dies for flat and formed components including connector housings, terminals, brackets, shields, gaskets, and electrical contacts. Tolerances to ±0.05 mm on punched profiles and ±0.1 mm on formed dimensions.
Copper Bus Bars & Bus Bar Components
Flat copper bus bars, drilled bus bars, bent bus bars, and custom bus bar fabrications for switchgear, panel boards, distribution boards, MCC panels, and battery systems. Manufactured from C11000 ETP copper to ASTM B187 with drilled holes, bent sections, and silver or tin plated surfaces as required.
Copper Electrical Shims & Washers
Precision-punched copper shims, washers, and gaskets for electrical, thermal, and mechanical applications. Available in precise thickness from 0.1 mm to 6 mm from C11000 ETP copper sheet for maximum conductivity and thermal performance.
Copper Clips, Springs & Contacts
Custom copper spring contacts, clips, and leaf spring components for electrical connectors, switches, battery contacts, and PCB spring terminals. Produced from C17200 beryllium copper, C72500 copper-nickel-tin, and C51000 phosphor bronze for optimal spring properties combined with good conductivity.
Copper Enclosures & Shields
Custom copper RF shielding cans, EMI shields, Faraday enclosures, and custom copper fabrications for electronics and telecommunications applications where electromagnetic shielding is required. Formed, seam-welded, or brazed per customer design.
Copper Heat Spreaders & Thermal Interface Components
Precision-cut and formed copper heat spreaders, vapor chamber blanks, heat sink bases, and thermal interface sheets for power electronics, LED lighting, and high-performance computing thermal management. ETP and oxygen-free copper for maximum thermal conductivity.
Copper Roofing & Architectural Panels
Custom-cut copper sheet panels, flashings, gutters, downspouts, decorative panels, and architectural copper components for roofing, building envelope, and historic restoration projects. Available in C11000 ETP copper in thicknesses from 0.5 mm to 3.0 mm (16 oz to 48 oz copper sheet).
Copper Grounding Components & Earthing Straps
Punched, formed, and drilled copper grounding plates, earthing lugs, copper bonding strips, and flexible copper braided straps for electrical grounding, lightning protection, and equipment earthing per NEC and NFPA 70 requirements.
Copper Gaskets & Sealing Components
Precision-cut copper gaskets and sealing rings for high-pressure, high-temperature, and corrosive environments including spark plug gaskets, exhaust manifold gaskets, hydraulic fittings, and instrument connections where copper’s malleability ensures reliable sealing.
Copper Sheet Metal Grades & International Equivalents
We process all commercially available copper sheet and strip grades. The table below details the most commonly used grades for sheet metal fabrication:
| Grade / Alloy | UNS (USA) | ASTM | BS (UK) | EN (Europe) | JIS (Japan) | Conductivity (% IACS) | Key Application |
|---|---|---|---|---|---|---|---|
| ETP Copper (C110) | C11000 | B152, B187 | C101 | CW004A / E-Cu58 | C1100 | >100% | Bus bars, heat spreaders, general electrical |
| Oxygen-Free Copper (OFC) | C10200 | B152, B170 | C103 | CW008A / OF-Cu | C1020 | ~100% | High-freq electronics, audio, vacuum |
| Phosphorus Deoxidized Cu | C12200 | B152 | C106 | CW024A / SW-Cu | C1220 | ~85% | Roofing, plumbing, brazeable components |
| Cartridge Brass (260) | C26000 | B36 | CZ106 | CW505L / CuZn30 | C2600 | ~28% | Deep-drawn cups, shells, decorative |
| Phosphor Bronze (510) | C51000 | B103 | PB102 | CW451K / CuSn4 | C5101 | ~15% | Springs, contacts, connectors |
| Beryllium Copper (172) | C17200 | B197 | CB101 | CW101C / CuBe2 | C1720 | ~22% | High-strength springs, precision contacts |
| Copper-Nickel 90/10 | C70600 | B122 | CN102 | CW352H / CuNi10Fe1Mn | C7060 | ~5% | Marine, heat exchanger fins |
Copper Sheet Metal Processing Capabilities
- Material Thickness Range: 0.1 mm to 10 mm (0.004″ to 0.394″) copper sheet and strip
- Sheet Size Handling: Up to 2,500 mm x 1,250 mm sheet format; coil-fed progressive tooling for high-volume production
- Processes Available: Blanking, piercing, progressive stamping, CNC punching, fiber laser cutting, bending (press brake), roll forming, deep drawing, embossing, coining
- Punching Tolerance: ±0.05 mm on punched profiles; ±0.1 mm on formed dimensions
- Laser Cutting: ±0.1 mm dimensional tolerance; minimum internal radius 0.5 mm; suitable for prototypes and low-medium volumes
- Forming: Press brake bending to ±0.5° angular tolerance; minimum bend radius 1x material thickness
- Joining: TIG/MIG welding, resistance spot welding, brazing, silver soldering, riveting
- Secondary Operations: Deburring, tumbling, passivation, tin plating, silver plating, nickel plating, lacquering
Industries We Serve Across the USA
- Electrical & Power Distribution: Bus bars, switchgear components, distribution panel hardware, grounding systems
- Electronics & PCB Manufacturing: RF shields, heat spreaders, contact springs, connector housings, EMI cans
- Automotive & EV: Battery interconnects, busbar assemblies, terminal components, shielding
- Renewable Energy: Solar PV system grounding, inverter bus bars, wind turbine current-carrying components
- Telecommunications: RF enclosures, antenna ground planes, cable shielding components
- HVAC & Refrigeration: Copper fins, heat exchanger end caps, refrigerant manifold parts
- Architectural & Roofing: Copper roofing panels, flashing, gutters, decorative architectural copper
- Medical & Laboratory: Shielding enclosures, thermal components, precision copper fixtures
Why Choose Brass & Copper Parts for Copper Sheet Metal Parts?
- Copper Sheet Metal Specialists: Unlike general sheet metal shops, we specialize exclusively in copper and copper alloy sheet metal fabrication — meaning better tooling, optimized processes, and deeper knowledge of copper’s unique forming characteristics.
- Full In-House Capability: From laser cutting and CNC punching for prototypes to progressive die stamping for high-volume production — we scale with your needs without changing suppliers.
- Material Expertise: We understand the springback, work-hardening, and annealing requirements of each copper alloy, ensuring accurate formed dimensions and consistent quality across all production runs.
- Bus Bar Fabrication Specialists: Complex bus bar assemblies with multiple bends, drilled hole patterns, and silver or tin plating — supplied ready to install in your switchgear or panel board.
- ISO 9001:2015 Certified: Full dimensional inspection with digital optical measurement systems, CMM verification for complex parts, and complete documentation packages.
- Competitive USA Market Pricing: Factory-direct manufacturing with DDP delivery to US customers. No brokering — we manufacture everything we sell.
- Fast Turnaround: Laser-cut and press-brake formed prototypes in 3–5 business days. Production tooling and progressive dies in 4–6 weeks. Production lead time 3–5 weeks thereafter.
Frequently Asked Questions — Copper Sheet Metal Parts
Q1: What copper sheet thickness is best for bus bars?
A: Bus bar thickness depends on the current-carrying requirements. As a general guide: for current ratings up to 200A, 3–6 mm thick C11000 ETP copper is typical; for 400–800A, 6–10 mm; for 1,000A and above, multiple parallel bars or thicker sections are used. We design bus bar cross-sections to ANSI/IEEE C37.20 or customer ampacity tables, accounting for temperature rise, material conductivity, and heat dissipation conditions.
Q2: Can you produce copper sheet metal parts to tight tolerances?
A: Yes. Laser cutting achieves ±0.1 mm positional accuracy on profiles. Progressive die stamping achieves ±0.05 mm on punched features with exceptional repeatability across high-volume runs. Formed dimensions (after press brake bending) are typically ±0.1 mm on linear dimensions and ±0.5° on angles. For tighter tolerances, coining and sizing operations are available.
Q3: What surface treatment do you recommend for copper bus bars?
A: For contact surfaces and joints, tin plating (bright or matte, 8–25 µm per ASTM B545) is the most common treatment for bus bars in switchgear and panel boards operating up to 105°C. Silver plating (15–25 µm per ASTM B700) is preferred for higher-temperature applications, high-current joints, and outdoor or corrosive environments. Both finishes dramatically reduce contact resistance and prevent the formation of non-conductive copper oxide on joint surfaces.
Q4: Can you cut and form copper sheet with complex profiles?
A: Yes. Our fiber laser cutting systems handle complex profiles, internal cutouts, slots, radii, and perforated patterns directly from 2D DXF/DWG files. For production volumes, progressive dies replicate these profiles at high speed with excellent repeatability. We also offer CNC punching with a full library of standard and special punch tooling for holes, slots, louvers, and embosses.
Q5: Do you offer copper sheet metal parts with complete assembly?
A: Yes. We provide turnkey sheet metal assembly including hardware insertion, welding, brazing, plating, and packing. We supply bus bar kits with all bolts, washers, and insulating hardware; shielding enclosure kits with lids and fasteners; and grounding assemblies ready to install — reducing your procurement and assembly burden.
Q6: What is the difference between ETP copper and oxygen-free copper for sheet metal parts?
A: For most sheet metal applications (bus bars, shielding, heat spreaders, general electrical), ETP copper (C11000) is the standard and most economical choice with excellent conductivity (>100% IACS). Oxygen-free copper (C10200) is specified for applications where hydrogen embrittlement is a risk (high-temperature reducing atmospheres), high-vacuum environments (electron tubes, semiconductors), or where the absolute minimum oxygen content is required for brazing or electron beam welding. The price premium for OFC is approximately 10–15% over ETP.
Q7: Can you supply copper sheet metal parts with RoHS and REACH compliance?
A: Yes. All copper sheet stock we process is sourced from certified suppliers with full material traceability. We provide RoHS 2 (Directive 2011/65/EU) and REACH (EC No. 1907/2006) compliance declarations with every shipment. Tin and silver plating materials also comply with RoHS requirements.
Copper Sheet Metal Design Guidelines
To help customers optimize their copper sheet metal designs for manufacturability and cost, our engineering team provides free DFM (Design for Manufacturability) review. Key guidelines include: minimum hole diameter should be at least equal to material thickness; minimum distance between holes should be 1.5x material thickness; minimum bend radius should be 1x material thickness for soft-temper copper and 1.5–2x for half-hard temper; bend relief slots at minimum 1.5x material thickness are recommended at intersecting bends. Following these guidelines reduces tooling cost and improves dimensional accuracy.
Quality Standards & Certifications
Brass & Copper Parts operates under ISO 9001:2015 certification. Copper sheet metal parts are manufactured in compliance with ASTM B152 (copper sheet, strip, and rolled bar), ASTM B187 (copper bus bar), ANSI/IEEE C37.20, and RoHS/REACH regulations. We provide dimensional inspection reports, material test certificates (MTCs), and certificates of conformance with all production orders. FAI (First Article Inspection) per AS9102 format is available for aerospace customers.
Get a Quote for Copper Sheet Metal Parts
Brass & Copper Parts is your trusted partner for precision copper sheet metal parts and components. From rapid-prototype laser-cut pieces to high-volume progressive stampings, we deliver quality, consistency, and value for USA customers. Upload your DXF, DWG, PDF, or STEP files today for a fast quotation — our engineering team will review your design and provide a competitive proposal within 24 hours.
