Copper Inserts – Copper Threaded Inserts

Premium Quality Copper and Copper Alloy Threaded Inserts for Industrial Applications

We are one of the leading manufacturers and exporters of Copper inserts and Copper threaded inserts from India. We have been supplying these critical fastening components to the world market for many decades. Our state-of-the-art manufacturing facility utilizes precision machinery and advanced production techniques to ensure superior quality and consistent performance. With an unwavering commitment to excellence, we have established ourselves as a trusted name in the global fastener industry. We also offer high conductivity Copper Parts, Copper components and Copper fasteners. Our extensive range of Copper inserts and Copper threaded inserts caters to diverse industrial requirements, offering exceptional thermal conductivity, electrical conductivity, and corrosion resistance. Our range of Copper CNC Parts Copper Machined Parts, Copper Terminals, Copper Connectors, Copper Contacts, Copper Machined Components and Copper Threaded Fasteners is well accepted worldwide.

Copper threaded inserts and Copper electrical inserts are specialized fastening components designed to provide strong, durable threads in softer materials such as plastics, wood, and non-ferrous metals. These precision-engineered components feature external knurling, barbs, or threading for secure anchoring in the parent material, while their internal threads accept standard machine screws or bolts. Leveraging Copper’s excellent thermal and electrical conductivity, corrosion resistance, and antimicrobial properties, our inserts provide superior performance in demanding applications where heat dissipation, electrical conductivity, or resistance to harsh environments is critical.

Copper Inserts -Material Grades

Our Copper threaded inserts are manufactured using premium-quality Copper alloys, each selected for specific performance characteristics:

Pure Copper (C11000) – 99.9% pure Copper with excellent electrical conductivity (101% IACS) and thermal conductivity (391 W/m·K), ideal for electrical applications.

Beryllium Copper (C17200) – High-strength Copper alloy containing 1.8-2.0% Beryllium, offering exceptional strength (up to 1400 MPa), excellent fatigue resistance, and good conductivity.

Phosphor Bronze (C51000) – Contains 3.5-4.5% tin and 0.03-0.35% phosphorus, providing excellent spring qualities, fatigue resistance, and corrosion resistance.

Brass (C26000, C36000) – Copper-zinc alloys offering good machinability, moderate strength, and excellent corrosion resistance at economical cost points.

Chromium Copper (C18200) – Contains 0.6-1.2% chromium, offering high strength while maintaining 80% of the conductivity of pure Copper.

All our materials comply with international standards including ASTM B152 (Copper), ASTM B196 (Beryllium Copper), ASTM B139 (Phosphor Bronze), and ASTM B453 (Copper-zinc-silicon alloys).

Manufacturing Processes

Our Copper threaded inserts are manufactured through a comprehensive multi-stage process designed to ensure precision, consistency, and superior quality:

Material Preparation:

• Precision alloy mixing according to international standards, Drawing or casting of Copper bars
• Specialized heat treatment for optimal material properties
• Rigorous material testing for conductivity, hardness, and composition

Forming Methods:

• CNC machining for complex geometries and tight tolerances
• Cold heading and impact extrusion for high-volume production
• Precision Casting/ Bars for complex designs with internal features
• Wire EDM for specialized configurations

Threading Operations:

• Thread rolling for superior thread strength and consistency
• CNC thread cutting for specialized thread profiles
• Precision thread grinding for ultra-fine thread tolerances

Finishing Processes:

• Deburring and edge rounding for safety and assembly ease
• Surface treatment and passivation for enhanced corrosion resistance
• Optional plating (tin, silver, gold) for specialized applications

Quality Control:

• 100% dimensional inspection using coordinate measuring machines (CMMs)
• Thread gauge verification for every production batch
• Material composition verification via spectrographic analysis
• Tensile strength and pull-out testing to ensure performance

Machinery and Equipment

Our state-of-the-art manufacturing facility utilizes advanced machinery to ensure precision, consistency, and efficiency:

Primary Production Equipment:

• CNC lathes (±0.005mm accuracy)
• Swiss-type automatic lathes for high-precision small parts
• Cold formers for high-volume production
• Thread rolling machines with control systems

Secondary Processing Equipment:

• Machining centers for complex geometries
• Precision grinding systems for critical dimensions
• Automated deburring and finishing stations
• Heat treatment furnaces with precision temperature control

Quality Control Equipment:

• VMM-CMM with accuracy to 0.001mm
• Thread profile analyzers and gauging systems
• Materials testing laboratory with spectrographic analyzers
• Environmental testing chambers for performance verification

Automation Systems:

• Automated material handling systems
• Vision-based inspection systems for 100% quality verification
• Real-time production monitoring and statistical process control

Typical Applications

Our Copper threaded inserts are utilized in a wide range of applications across diverse industries:

Electronics and Electrical Equipment:

• Power distribution components requiring high conductivity
• Heat sinks and thermal management systems
• PCB standoffs and mounting hardware
• RF and microwave equipment connections
• Grounding and EMI shielding components

Automotive and Transportation:

• Electric vehicle battery terminals and busbars
• Thermal management systems for power electronics
• Sensor housing connections in harsh environments
• Electromagnetic interference (EMI) shielding components
• High-current electrical connectors

Aerospace and Defense:

• Avionics mounting systems requiring EMI shielding
• Thermal management components in critical systems
• Radar and communication equipment connections
• High-reliability electrical junction points
• Lightweight structural connections in composite materials

Industrial Equipment:

• Power generation and distribution components
• Process control instrumentation connections
• High-temperature equipment fittings
• Corrosion-resistant threaded connections in chemical processing
• Robotic system electrical and mechanical connections

Medical Devices:

• Antimicrobial threaded connections for medical equipment
• Imaging system components requiring EMI shielding
• Patient monitoring equipment connections
• Sterilizable threaded components for surgical instruments
• Rehabilitation equipment mechanical connections

Renewable Energy:

• Solar panel mounting and connection systems
• Wind turbine electrical connections requiring vibration resistance
• Hydrogen fuel cell electrical interfaces
• Energy storage system connections
• Marine-grade corrosion-resistant fastening systems

Surface Finishes

We offer a variety of surface finishes to enhance performance characteristics and meet specific application requirements:

Standard Finishes:

• Natural (uncoated) – Maximum electrical and thermal conductivity
• Bright dipped – Enhanced appearance and modest corrosion protection
• Passivated – Improved corrosion resistance without sacrificing conductivity

Enhanced Protection Finishes:

• Tin plating (2-8μm) – Excellent solderability and good corrosion protection
• Nickel plating (5-25μm) – Superior wear resistance and corrosion protection
• Silver plating (2-5μm) – Premium electrical conductivity and tarnish resistance

All finishes comply with relevant international standards including RoHS, REACH, and industry-specific requirements.

Performance Metrics

Our Copper threaded inserts deliver exceptional performance across critical metrics:

Mechanical Properties:

Electrical Properties:

Thermal Properties:

Environmental Resistance:

Quality Assurance and Specifications

Our Copper threaded inserts are manufactured to meet or exceed leading international standards:

Thread Standards:

• Metric threads per ISO 965 (tolerance classes 4H, 5H, 6H available)
• Imperial threads per ASME B1.1 (class 2B and 3B available)

Material Standards:

• ASTM B152/B152M – Standard for Copper Sheet, Strip, Plate, and Rolled Bar
• ASTM B196/B196M – Standard for Copper-Beryllium Alloy Rod and Bar
• ASTM B139/B139M – Standard for Phosphor Bronze Rod, Bar, and Shapes
• ISO 427 – Wrought Copper-Tin Alloys – Chemical Composition and Forms
• JIS H3250 – Copper and Copper Alloy Sheets, Plates and Strips

Quality System Certifications:

• ISO 9001:2015 – Quality Management Systems
• ISO 14001:2015 – Environmental Management Systems
• IATF 16949:2016 – Automotive Quality Management
• AS9100D – Aerospace Quality Management

Industry-Specific Compliance:

• RoHS 2015/863/EU – Restriction of Hazardous Substances
• REACH Regulation EC 1907/2006 – Chemical Substance Registration
• FDA 21 CFR 177 – Food Contact Materials (select finishes)
• MIL-I-45208A – Military Inspection Requirements

Tolerances on our range of Copper Inserts Molding Inserts, Threaded Copper Inserts

Our manufacturing processes ensure precision and consistency across all dimensions:

Internal Thread Dimensions:

• Classes 4H, 5H, 6H per ISO 965 (metric threads)
• Classes 2B, 3B per ASME B1.1 (imperial threads)
• Thread pitch diameter: ±0.013mm (±0.0005″)
• Thread major diameter: ±0.025mm (±0.001″)
• Thread minor diameter: ±0.025mm (±0.001″)

External Dimensions:

• Outside diameter: ±0.025mm (±0.001″)
• Length: ±0.13mm (±0.005″)
• Concentricity: 0.05mm (0.002″) T.I.R.
• Perpendicularity: 0.025mm (0.001″) per 25.4mm (1″)
• Surface roughness: 0.8-3.2 μm Ra (application dependent)

Specialized Features:

• Knurl depth: ±0.05mm (±0.002″)
• Hex drive features: H12 tolerance per ISO 286-2
• Countersink angle: ±1°
• Chamfer dimensions: ±0.13mm (±0.005″)

All tolerances can be customized to meet specific application requirements upon request.

Turnaround Time and Production Capacity

Standard Production Timeline:

• Standard catalog items: 1-2 weeks
• Custom orders with existing tooling: 2-3 weeks
• New custom designs requiring tooling: 4-6 weeks
• High-priority rush orders: Available upon request (additional fees may apply)

Production Capacity:

• Monthly production capacity: 5+ million units
• Minimum order quantity (MOQ): 1,000 units for standard items
• MOQ for custom designs: 5,000 units (may vary based on complexity)
• Prototype quantities available for new designs (25-100 pieces)

Order Processing:

• Quote response: Within 24-48 hours
• Order acknowledgment: Same business day
• Production updates: Weekly progress reports
• Quality documentation: Provided with each shipment

Why Choose Our Copper Inserts Copper Threaded Inserts?

Technical Excellence:

• Industry-leading dimensional precision and consistency
• Comprehensive material selection for optimized performance
• Advanced manufacturing processes ensuring superior quality
• Extensive testing and validation for every production batch

Business Advantages:

• Global manufacturing experience spanning three decades
• Flexible production scheduling to meet changing demands
• Competitive pricing through manufacturing efficiency
• Comprehensive technical support from design through implementation

Customer-Centric Approach:

• Dedicated account management for seamless communication
• Engineering support for product selection and application
• Custom design services to meet unique requirements
• Expedited sampling for new product development

Global Capabilities:

• Multi-lingual technical and sales support
• International logistics expertise
• Familiarity with import/export requirements
• Experience with global OEMs and tier suppliers

Sustainability Commitment:

• Energy-efficient manufacturing processes
• Responsible material sourcing
• Recycling programs for production scrap
• RoHS and REACH compliant products

Customization Capabilities for Copper Inserts

We offer extensive customization options to meet your specific requirements: Custom thread sizes and profiles,Flexible batch sizes to match your production schedule and Custom inspection criteria and reporting.

FAQs

Q1: What advantages do Copper threaded inserts offer compared to other materials?

A1: Copper threaded inserts provide several distinct advantages:

• Superior thermal conductivity (up to 391 W/m·K) for heat-critical applications
• Excellent electrical conductivity (up to 101% IACS) for electrical connections
• Natural antimicrobial properties that inhibit bacterial growth
• Good corrosion resistance, particularly in marine environments
• Excellent formability while maintaining good mechanical strength
• Compatibility with a wide range of plating and finishing options

Q2: How do I select the right Copper alloy for my application?

A2: The optimal Copper alloy depends on your specific requirements:

• Pure Copper (C11000): Best for maximum electrical and thermal conductivity
• Beryllium Copper: Ideal for high-strength applications requiring good conductivity
• Phosphor Bronze: Best for spring properties and wear resistance
• Brass: Economical choice with good machinability and moderate strength
• Chromium Copper: High strength while maintaining good conductivity

Our engineering team can assist with material selection based on your specific performance requirements.

Q3: What thread sizes and configurations are available?

A3: We offer a comprehensive range of thread sizes:

• Metric: M2 to M20
• Imperial: #0-80 to 3

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