Copper Deep Drawn Sheet Metal Parts

Copper Deep Drawn Sheet Metal Parts

Copper deep drawn sheet metal parts are seamless hollow components formed by progressive drawing of copper sheet through a die to produce cups, shells, capsules, cans, housings, enclosures, and formed profiles. Also known as copper deep drawing components, copper drawn cups, copper cold-drawn shells, copper seamless capsules, copper drawn cans, copper drawn contacts, copper drawn bushings, and copper formed housings, these parts are manufactured from Cu-ETP (C11000), Cu-DHP (C12200), and Cu-OF (C10200) copper sheet by Electrical Accessories India. Used in electrical components, electronic connectors, precision instruments, medical devices, and industrial hardware.

Product Overview

Copper Drawn Cups and Shells

Copper drawn cups, copper drawn shells, copper drawn cylinders, copper drawn blanks, and copper open-end cups are produced by single or multi-stage deep drawing. Single-draw cups have depth-to-diameter ratios up to 0.7:1; re-draw operations achieve 2:1 or higher for deep capsule profiles. Applications include battery contact terminals, capacitor casings, solenoid coil forms, relay contact housings, pressure transducer diaphragm caps, and hermetic sealing cups for electronic devices. Wall thickness of deep-drawn copper cups ranges from 0.3–3.0 mm depending on starting material and drawing ratio.

Copper Drawn Contact Housings and Connectors

Copper drawn contact housings, copper socket contacts, copper deep drawn terminal bodies, copper drawn connector housings, and copper drawn spring contacts are used in electrical connectors, automotive terminals, and relay bases. The seamless wall of a deep-drawn part offers superior mechanical integrity compared to stamped-and-formed alternatives. Copper’s high conductivity ensures that the drawn housing does not add measurable resistance to the contact assembly. Progressive drawing combined with edge-trimming and piercing produces complete functional connector housings from a single copper disc.

Copper Capsules and Hermetic Sealing Components

Copper hermetic capsules, copper sealing cups, copper drawn pressure capsules, and copper Bourdon tube blanks are used in pressure instruments, temperature sensors, barometric instruments, and hermetic electronic packages. These require very close dimensional tolerances and smooth internal and external surfaces. Cu-OF copper is preferred for hermetic applications where hydrogen atmosphere brazing or vacuum environment is used. Deep-drawn copper capsules are brazed or welded closed to form hermetically sealed sensor bodies rated to pressures up to 100 bar.

Copper Heat Exchanger Components

Copper drawn heat exchanger caps, copper tube end plates, copper header caps, copper tube stub ends, and copper expansion bottle closures are manufactured by deep drawing from heavy copper sheet. Heat exchanger end caps and tube plates use Cu-DHP for brazability and water compatibility. Drawn copper collector boxes for solar thermal flat plate collectors are produced from 0.5–1.5 mm Cu-DHP sheet. Custom drawn profiles for copper heat exchanger end assemblies are manufactured to OEM engineering drawings with weld preparation edges formed into the drawn profile.

Copper Electronic and Precision Drawn Parts

Copper drawn shields, copper RF shielding cans, copper EMI enclosures, copper drawn relay cans, copper drawn motor commutator caps, copper drawn bearing retainers, and copper drawn waveguide components are manufactured for electronics and precision instrument applications. The seamless drawn profile provides superior EMI shielding compared to fabricated boxes. Cu-ETP or Cu-OF is used for high-conductivity shielding; copper’s skin depth at 1 MHz is 65 μm, requiring wall thickness of at least 3–5× skin depth for effective shielding. These drawn parts are used in telecommunications, radar, medical imaging, and scientific instruments.

Key Features

• Seamless deep-drawn construction — no welds, higher structural integrity
• Cu-ETP, Cu-DHP, and Cu-OF copper grades to application requirement
• Single-draw or multi-stage re-draw for depth:diameter up to 2:1+
• Wall thickness range: 0.3 mm to 3.0 mm depending on profile
• Close tolerance: ±0.05–0.1 mm OD; ±0.1 mm depth
• Available with trimmed, flanged, beaded, or ironed walls
• Custom profiles to OEM drawing in any copper alloy
• Full material and dimensional documentation standard

Deep Drawing Process and Formability

Copper is one of the most formable metals for deep drawing. Cu-ETP and Cu-DHP in annealed (O-temper) condition achieve drawing ratios (blank diameter to punch diameter) of 2.0–2.2 in a single draw, exceeding aluminium (2.0) and approaching the theoretical limit for isotropic sheet. Intermediate annealing between drawing stages restores ductility, allowing multi-stage drawing to depth:diameter ratios of 3:1 or higher. Lubrication with drawing oil prevents galling and surface scoring. The drawn wall thins slightly (typically 5–15% reduction) from blank thickness, which is accounted for in blank design.

Dimensional Precision and Tolerances

Deep drawn copper parts are produced to ±0.05 mm on OD (controlled by die bore), ±0.1 mm on ID (controlled by punch diameter), ±0.1 mm on depth after trimming, and ±0.05 mm on wall thickness (related to blank thickness tolerance and drawing reduction). Flanged parts have flange flatness of ±0.2 mm. Trimming is performed by rotary trimming tool or CNC lathe for precise length. For hermetic electronic packages, tighter tolerances of ±0.025 mm OD and ±0.025 mm depth are achievable.

Surface Quality and Finishing

Deep-drawn copper surfaces have Ra 0.4–1.6 μm (outer die surface) and Ra 0.8–3.2 μm (inner punch surface) as drawn. Electropolishing or buffing reduces to Ra <0.2 μm for optical and precision applications. Tin plating (5–15 μm), silver plating (5–25 μm), or nickel plating (3–10 μm) is applied after drawing and annealing. Drawing oil residue is removed by alkaline degreasing and acid pickling before any plating operation. Edge quality after trimming: trimmed burr <0.05 mm; flanged edges are smooth and defect-free.

Intermediate Annealing and Temper Control

Complex deep drawn profiles requiring multiple drawing stages incorporate intermediate annealing at 400–600°C to restore full ductility before the next drawing stage. Final temper depends on application: annealed (soft) for hermetic brazing and soldering; work-hardened (light draw without annealing) for spring contact housings. Temper is specified per the part drawing. In-process hardness testing (Vickers) is performed after annealing to verify full softness (40–60 HV for Cu-ETP annealed).

Tooling and Prototyping

Single-station draw dies are used for prototype and low-volume production (50–500 pieces). Progressive transfer dies produce high volumes (1000+ pieces/hour) for standard capsule and cup profiles. New tooling lead time: 3–5 weeks for simple profiles; 6–8 weeks for complex multi-stage progressive tools. DFM (design for manufacturability) review is included for all new part enquiries to optimise blank size, drawing ratio, and annealing schedule.

Technical Specifications

Material Grades and International Equivalents

Product Types and Variants

Open-end cups (single draw); closed-end cups; capsules (closed both ends by assembly); cylindrical shells; flanged cups; beaded cups; ironed-wall cups (precision wall thickness); re-drawn shells (deep profiles); contact housings; RF shielding cans; heat exchanger end caps; pressure capsules; custom shapes to OEM drawing.

Applications in Industry

Battery contact terminal caps; capacitor casing shells; relay contact housings; pressure sensor capsules; Bourdon tube blanks; hermetic electronic package bodies; solar collector manifold caps; heat exchanger tube end caps; RF/EMI shielding enclosures; solenoid coil forms; medical device housings; automotive connector terminal bodies.

Manufacturing Process

1. Blank design — DFM review; optimise blank diameter for draw ratio
2. Copper sheet/coil procurement — ASTM B152/B187 with MTC
3. Blanking — disc blanks punched from coil
4. Drawing (stage 1) — first draw to intermediate cup
5. Intermediate annealing (if multi-stage) — 400–600°C, air cool
6. Re-drawing (stages 2, 3…) — to final profile
7. Trimming — rotary trim to final depth
8. Flanging/beading (if required) — CNC or die operations
9. Cleaning — alkaline degreasing, acid rinse
10. Plating (if required) — tin, silver, nickel
11. Final inspection — OD, ID, depth, wall thickness, surface

Quality Standards and Certifications

Material: ASTM B152, B187, BS EN 13601. Dimensions: to OEM drawing with agreed tolerances. ISO 9001:2015 QMS. REACH and RoHS compliance. EN 10204 Type 3.1 MTCs standard.

Why Choose Electrical Accessories India

Electrical Accessories India manufactures custom copper deep drawn parts at its Jamnagar facility. Our press shop operates single-station and progressive transfer dies for copper cups, shells, and capsules. DFM support, intermediate annealing, and close-tolerance trimming are performed in-house. We supply prototypes and scale to high-volume production. Full documentation standard with each shipment.

Frequently Asked Questions (FAQ)

What is deep drawing?

Deep drawing is a sheet metal forming process where a flat copper blank is drawn through a die by a punch to form a seamless hollow shape. “Deep” drawing means the depth of the drawn part exceeds half its diameter, distinguishing it from shallow forming operations.

What depth-to-diameter ratio is achievable in copper deep drawing?

In a single draw, depth:diameter ratios up to 0.7–0.8:1 are typical. With intermediate annealing and re-drawing, ratios of 2:1 or higher are achievable for complex capsule profiles.

What copper grade is recommended for deep drawing?

Annealed Cu-ETP (C11000) or Cu-DHP (C12200) are the most formable grades. Cu-OF (C10200) is preferred for hermetic applications. Half-hard or hard temper copper is not suitable for deep drawing.

Can the wall thickness be uniform in a deep drawn copper part?

Yes, through ironing (wall ironing). Without ironing, the wall thickens at the base and thins at the top. Ironing uses a close-clearance die to reduce and equalise wall thickness during the final drawing pass. Tolerance on ironed wall thickness: ±0.025 mm.

What is the tooling cost for custom deep drawn copper parts?

Single-station draw die tooling: approximately from USD 800–3000 depending on size and complexity. Progressive transfer die tooling: USD 3000–15000+. Tooling is amortised over minimum production quantities agreed at order.

What is the minimum order quantity?

Prototype with single-station tooling: 50–100 pieces. Production minimum with existing tooling: 500 pieces. New progressive tooling: typically 2000 pieces minimum for tooling amortisation.

Are copper deep drawn parts available with silver plating?

Yes. Silver-plated deep drawn copper housings and contact shells are a standard product for connector applications. We apply rack silver plating (5–50 μm) after drawing and cleaning.

Can dimensions be held to ±0.025 mm on deep drawn copper?

Yes, on controlled dimensions (OD is controlled by die; ID by punch). Tighter tolerances require precision grinding of tooling and controlled blank thickness tolerance. Contact us for DFM discussion on tight-tolerance parts.

Equivalent Terms – Multilingual Reference

Related Products and Linked Terms

• Copper Pressing and Copper Pressed Parts
• Copper Busbar Links – Flexible Busbar Connectors
• Copper Grounding Terminals – Earth Terminals
• Copper Earthing Tags – Earth Tags and Grounding Labels
• Copper Switch Contacts – Electrical Contact Tips
• Copper Fuse Clips – Pressed Copper Fuse Clips
• Copper Shims and Copper Shim Washers
• Copper Washers and Copper Plain Washers
• Copper Sealing Washers – Crush Washers
• Copper Pipe Brackets and Copper Pipe Clamps
• Copper Deep Drawn Sheet Metal Parts
• Copper Machined Parts

Indicative Pricing

Copper Items: US$ 15.80 per kilogram, CIF USA Port

Prices are indicative and subject to change based on quantity, specification, alloy grade, and market conditions. Contact us with your RFQ for a firm quotation.

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