Copper, thanks to its exceptionally high electrical and thermal conductivity, is a material of strategic importance in many industries, from automotive and electronics to energy and aviation. Copper components are irreplaceable where high conductivity, durability and corrosion resistance are required. However, copper processing poses a number of challenges for manufacturers: the softness of the material, its thermal properties, surface reactions and aspects related to copper recycling require a specialised approach.
Copper properties relevant to machining
High electrical and thermal conductivity
Copper properties such as the very high electrical conductivity of copper (e.g. copper CW004A) of approx. 58 MS/m make it the second best conductor after silver. Thermal conductivity of up to 390 W/mK allows for rapid heat dissipation, but creates a risk of local overheating during machining. This necessitates the use of adequate cooling throughout the process, as well as the selection of tools that reduce friction.
Plasticity and machinability
Copper is a soft and viscoplastic material, which makes it easy to shape, but at the same time makes it difficult to achieve narrow tolerances in CNC machining of copper. When milling or turning copper, tools can easily become clogged and burrs can form. It is therefore necessary to use specialised tools and adjusted cutting parameters.
Choosing the right copper alloys
Copper alloys with increased mechanical strength
In applications requiring greater mechanical strength, alloys such as copper CW021A are used, which combine conductivity with increased durability. These types of copper alloys retain good machinability while enabling the manufacture of components that operate under load.
The effect of alloying additives on conductivity and durability
Additives such as tin, zinc or silver affect the microscopic structure of the material. The right choice of alloy allows a compromise to be achieved between the electrical conductivity of copper and mechanical strength and corrosion resistance.
In mass production, it is therefore worth working with an experienced manufacturer such as RADMOT. We select the right material for the working conditions and design requirements - discover our modern CNC machine park, where we carry out orders.
Copper machining techniques ensuring high quality components
Copper milling – precise shaping of elements
Professional copper milling allows for the production of details with complex geometry while maintaining narrow copper machining tolerances. The selection of high-sharpness tools and proper cooling are of key importance here. Thanks to modern RADMOT machining centres, it is possible to obtain smooth surfaces and minimise any edge defects.
Copper turning – creating cylindrical components
CNC turning is suitable for the production of rings, sleeves and other rotating components. Copper requires rigid clamping and high precision tools. The use of specialised cutting plates for soft metals significantly improves the durability of the blades and allows for good surface quality to be maintained. Precision CNC turning – see what we offer at RADMOT.
CNC machining of copper – automation and repeatability
The large-scale precision machining of copper offered by RADMOT guarantees repeatability of dimensions and optimisation of production costs. Our modern machine park enables us to carry out orders with a high degree of complexity and accuracy.
Copper surface finishing for increased durability
Glass bead blasting – improving aesthetics and surface properties
Glass bead blasting is a form of micro-grinding that removes impurities and smooths the metal structure. Copper components undergo this process to improve their wear resistance and appearance, which is important in consumer electronics, among other things.
Protective coatings – protection against oxidation
Processes such as silver plating, nickel plating and zinc plating are used to protect against oxidation and improve the conductivity of copper. Copper silver plating is particularly recommended for current-conducting parts, as it maintains excellent contact conductivity.
Heat treatment – modification of the crystal structure to increase strength
Heat treatment removes stresses caused during copper cutting and increases its resistance to material fatigue. This process requires precise control of temperature and duration so as not to reduce electrical conductivity.
RADMOT also offers services dedicated to other materials such as steel and aluminium. Anodising of aluminium parts – durability and aesthetics, which we provide in as many as 12 colours, will meet the requirements of every customer.
Quality control and testing of copper components
Visual inspection and dimensional control
Copper components must undergo a detailed visual inspection and dimensional measurements. RADMOT has one of the largest measurement facilities in Poland, enabling the control of narrow tolerances and compliance with technical documentation, even in serial production. Copper processing – high conductivity components from RADMOT are always comprehensively tested.
Examples of copper component applications in industry
The use of copper in industry is very widespread and popular. Copper parts are used, among other things, in cooling systems, busbars, transformers, high-current connectors, heating elements and precision electronic components. In each of these industries, the key factors are: reliability, corrosion resistance and electrical conductivity of copper.
Summary and recommendations
Key factors affecting the quality of copper machining
The selection of the right alloy, copper machining tools, precision milling or turning, and the use of appropriate protective coatings are crucial for obtaining durable, efficient components. Copper machining requires experience and material knowledge.
The importance of selecting the right techniques and materials
Only a comprehensive approach – from material selection, through cutting technology, to copper surface finishing – guarantees the full functionality of copper parts in a given application.
The choice of a manufacturing partner with extensive technological resources has a direct impact on the quality of the final product. RADMOT offers comprehensive services in one place. Professional CNC milling – check out our services and choose the optimal solution for your project needs.
The role of experience and technology in the production of copper components
RADMOT, as an experienced manufacturer of copper parts, offers full engineering support, modern machinery and comprehensive services - from CNC milling and turning to prototyping and surface treatment. The combination of all these competences guarantees that your order will be completed reliably. Would you like to receive a quote for the production of copper components? Send us your enquiry and we will prepare an individual offer for you.
