Time to read: 9 min
Copper is an incredible metal and element that powers the world in various applications, from electronics to piping, and even as a coenzyme in the human body.
What is Copper?
Copper is likely powering something near you at this very moment. Derived from the Latin word Cuprum meaning “from Cyprus,” Copper (Cu) has been used by humans for over 10,000 years, since as early as 8,000 BC. As one of the few metals found in pure form in nature, copper is both versatile and essential, with applications in everything from electrical wiring to mechanical parts and water pipes.
In chemistry, copper is known as Cu on the periodic table and has an atomic number of 29. It is a reddish, nonferrous metal that is one of the “transition metals” alongside silver and gold. Copper’s high electrical conductivity makes it a great option for use in electronics. Additionally, copper is ductile and malleable, making it a versatile material that can be shaped into wires, tubes, and other forms relatively easily while maintaining its mechanical strength.
Properties of Copper
There are several factors to keep in mind when considering copper for mechanical parts and products:
- The type of copper or alloy
- The material cost
- The manufacturing method
- The environment in which the part or product is to serve
- The strength, durability, and conductivity that the application requires
Let’s look at valuable copper properties:
- Workability: Copper can be easily soldered, brazed, or welded to form substantial and durable joints among parts. It is easily alloyed to increase its strength and durability to suit specific applications.
- Thermal Conductivity: Copper’s use in mechanical parts and products is often attributed to its heat dissipation capability. Because copper’s thermal conductivity is higher than that of other metals with similar strength, it can be used in heat exchangers, such as radiators. This property improves efficiency in several mechanical systems and reduces overheating risks.
- Electrical conductivity: Copper is known for its exceptional electrical conductivity, making it a preferred choice for electrical wiring and components. Its ability to efficiently conduct electric current is second only to silver, but due to its cost-effectiveness and availability, it is often used as the standard for electrical applications.
- Antibacterial Tendency: Antimicrobial properties in copper help inhibit the growth of bacteria and other microorganisms on surfaces.
- Corrosion Resistance: Copper is fairly resistant to corrosion, compared to other metals, which makes it suitable for outdoor applications and environments with high moisture or salt levels.
These properties make copper a great choice for specific applications. If you’re still unsure if copper is right choice for your product, keep reading or use our materials AI assistant to investigate alternative material options.
How Copper is Used in Manufacturing
Copper is a remarkably adaptable material, manufactured through various processes such as casting, forging, and extrusion into various shapes and sizes. This versatility makes copper an essential component in many mechanical parts and products.
Copper CNC Machining
When it comes to CNC machining, copper is often favored for its excellent formability. However, being a softer metal, pure copper can lead to considerable tool wear. To counteract this, selecting the right cutting tools and machining parameters is crucial. Often, using copper alloys is a better choice as they maintain desirable characteristics while providing improved machinability.
Copper’s excellent conductivity and malleability make it a sought-after material for CNC machining, particularly in high-performance electrical and thermal applications. At Fictiv, we provide precision CNC machining services for copper and its alloys, offering tolerances as tight as ±0.0001”.
Copper in Injection Molding and EDM Electrodes
Copper is also used as an electrode in Electrical Discharge Machining (EDM), which allows for precise machining even in small areas. EDM is particularly useful in creating and modifying tools for injection molding.
The molds themselves can even be made from beryllium-copper alloy, providing excellent thermal conductivity. There is also Copper Injection Molding (CuMIM) technology that is used for manufacturing high-complexity heatsinks, but this is not the same as using copper for the molds themselves.
Copper Sheet Metal
Copper sheet metal is particularly valued for its combination of durability, flexibility, and aesthetic appeal. It can be easily formed into intricate designs, making it ideal for decorative applications as well as functional components in electronics, HVAC systems, and architectural features. The high thermal and electrical conductivity of copper sheet metal further enhances its desirability, especially in applications that require efficient heat dissipation or electrical connectivity.
With Fictiv’s advanced sheet metal fabrication services, we can deliver high-quality copper parts with tight tolerances of up to ±0.0003”. Our services include laser cutting, bending, forming, and finishing options like anodizing and plating, ensuring your parts meet both functional and aesthetic requirements.
Copper Die Casting
Copper die casting is a specialized process that leverages the excellent fluidity and low shrinkage of copper alloys to produce intricate and precise components. This technique involves forcing molten copper into a mold under high pressure, allowing for the creation of complex shapes with tight tolerances. One of the key benefits of copper die casting is its ability to achieve high dimensional accuracy and a superior surface finish, reducing the need for extensive post-processing.
Copper Electroplating
Copper electroplating is a process that is widely used to enhance the appearance, performance, conductivity, and corrosion resistance of various components across multiple industries. This electrochemical technique involves depositing a thin, uniform layer of copper onto a substrate—such as steel or aluminum—by immersing it in an electrolyte solution containing copper ions. Electroplating not only improves electrical conductivity but also enhances thermal management, making it ideal for semiconductors, aerospace components, and power transmission systems.
Industrial Applications for Copper Manufacturing
Copper has a wide range of technological applications because it is electrically and thermally conductive, malleable, and ductile. In fact, certain copper properties have made it an inseparable part of the development and advancement of various technologies, from electrical wiring to renewable energy systems. The following are some key areas of the technological use of copper:
- Electrical Wiring: The major application of copper in electrical wiring used in homes, buildings, and electrical grids gives it the widest application area. The high electrical conductivity of the material allows the transmission of electricity at very minimal energy losses.
- Electronics: Copper is used in the manufacture of electronic devices, such as computers, mobile phones, and televisions. The metal is applied to the printed circuit boards, which are the backbones of electronic devices since they help in connecting various electronic components.
- Power Generation and Transmission: Besides finding applications in power transmission lines, copper is used in power generation machinery, transformers, and generators. Its high thermal conductivity helps dissipate the heat generated effectively, thus adding to the efficiency of a given operation.
- Telecommunications: Copper is utilized in the development of telephone lines, coaxial cables, and even fiber-optic cables. In such applications, copper facilitates voice, data, and even video transmissions over longer distances with less signal degradation.
- Renewable Energy: Copper is vital in the research, development, and functionality of renewable energy technologies, such as wind turbines and photovoltaic panels. It is applied in the generators, transformers, and electric power transferral systems associated with these technologies.
- Heating and Cooling Systems: Copper is an excellent heat conductor and is in use with all types of heating and cooling systems, including radiators, heat exchangers, and refrigeration machinery. Its high thermal conductivity offers great efficiency in heat transfer and distribution of energy.
- Medical Devices: Copper is used in several key medical devices, including surgical appliances, orthopedic implants, and radiotherapy equipment. Its biocompatibility and antimicrobial properties extend its range of applications in healthcare.
- Musical Instruments: Copper alloys are valued for their acoustic properties; a large number of quality brass instruments and hardware are manufactured from copper alloys.
- Pipes: Antimicrobial properties further copper’s suitability for use in water pipes, filtration systems, and zero-level contamination water transfer.
- Kitchen Appliances: Copper is used throughout the kitchen in everything from sinks to pots and pans, mugs, electrical fittings, and light housings.
Copper Applications in Emerging Industries
Copper plays a critical role in the advancement of industries like EVs, semiconductors, and climate tech. Fictiv supports these sectors with high-precision custom copper parts that enhance conductivity, energy efficiency, and sustainability. Whether you need copper busbars for power distribution, heat sinks for semiconductor cooling, or corrosion-resistant components for renewable energy applications, our global manufacturing network ensures reliable, scalable production.
Benefits and Limitations of Using Copper Beyond Manufacturing
Benefits of Copper
Copper has many other interesting attributes that make it beneficial in other applications beyond manufacturing. First, copper is widely recyclable. Recycled copper can serve just like new copper in any application, making the environmental impact of copper production relatively low by preserving natural resources. Also, compared with most metals such as lead and mercury, copper mining and production have a relatively small environmental impact.
Copper is also a natural fungicide and prevents the growth of algae and other organisms in water. This makes copper suitable for water pipes and other fittings involving water. Health benefits like improved circulation and reduction of inflammation in the body have also been associated with copper.
Limitations of Copper
Despite the advantages, there are also several limitations to consider. First, there is the cost of copper, which is somewhat higher compared to many other metals. This may make copper an expensive option for common applications. However, the disadvantages are often outweighed by advantages such as durability, conductivity, and resistance to corrosion, which provide value for money, especially in long-term applications.
Another potential disadvantage of using copper is its weight. Copper is a moderately heavy metal, and for this reason, it may be less suitable for applications where there is concern about the overall weight. Generally, however, ample strength and resilience make copper suitable for parts requiring load-carrying ability and resistance to friction and heat.
Copper Types and Alloys
There are various types of copper available, each with its own properties and characteristics. They can be divided into the following families:
- Pure copper: 99.3% pure or higher
- High copper alloys: 96%–99.3% pure
- Brass: Includes zinc brass, tin brass, and leaded brass
- Bronze: Includes phosphor bronze, leaded phosphor bronze, aluminum bronze, and silicon bronze
- Other alloy groups: Includes copper-nickel alloys, copper-nickel-zinc alloys, leaded coppers, free machining coppers, and special alloy coppers
| Copper Alloy Family | Alloying Metals & % Composition | Copper Alloys in Family | Important Properties | Common Industry Applications |
| Pure Copper | Copper 101: Copper: 99.9%Oxygen: 0.001% | Copper 101, Copper 102 | High corrosion resistance, ductility, and malleability, superiorly high electrical and thermal conductivity, low hardness and volume resistivity, not very strong | Semi-conductors, indoor/outdoor building materials, cables and thin wires, household products, heat exchangers, metal cylinders, coins, electronics components, aerospace parts, power transmission lines |
| Copper 102: Copper 99.95%Oxygen: 0.001% | ||||
| Brass | Copper: 55-95% | 360 Brass, 70/30 Brass, Free Cutting Brass, 272 Brass | Malleable, ductile, anti-microbial, low-friction | Musical instruments, decorative objects, locks, non-spark tooling, heat exchanger cores, fasteners, plumbing components |
| Zinc: <~43% | ||||
| Lead: <0.03-4.5% | ||||
| Gliding Metal | Copper: 90-95% | C22000 (Red Brass), C23000 (Commercial Bronze), C24000, C21630 | Lower rate of work hardening, moderate strength, ability to be deep drawn, durable, superior stress corrosion cracking resistance, excellent solderability and brazeability | Cosmetic hardware, building materials, tubing, writing instruments |
| Iron: 0.05% Max | ||||
| Lead: 0.02% Max | ||||
| Zinc: 5-10% | ||||
| Bronze | Copper: 80-97% | 932 Bearing Bronze (C93200), B20, B8, Statuary Bronze | High strength, resistance to corrosion, and electrical conductivity | Tools, musical instruments, decorative objects like ornaments or statues, bearings, electrical contacts/relays, automotive parts |
| Tin: 3-20% | ||||
| Cupronickel | Copper:70-90% | Monel 400, C70600 (90/10), C71500 (70/30) | Has a silver coloring, improved strength, and corrosion resistance; good ductility | Marine hardware parts, coins, thermocouples, strain gauges |
| Nickel: 10-30% | ||||
| Beryllium Copper | Copper: 95-99.6% Beryllium: 0.4-5% | C17200, C17300, C17500, C17510 | High strength, hardness, and conductivity, excellent corrosion resistance | Connectors, switches, and various electrical components |
| Cadmium Copper | Copper: 98-99% | Copper 162 (C16200) | Excellent flex life combined with good tensile strength, high electrical conductivity, and thermal stability | Electrical components, transmission lines |
| Cadmium: 0.1-1.5% |
Table 1: Composition, properties, and common uses for copper alloys.
Conclusion
Copper is an important and widely used material in mechanical parts and products due to its high electrical and thermal conductivity, as well as its malleability, and ductility. In all cases of copper usage in mechanical applications, the requirements of the application need to be considered and the copper type chosen accordingly based on those requirements.
With its resistance to corrosion, antimicrobial properties, and sustainability, copper is an outstanding material for mechanical parts and products. The disadvantages of copper, such as its cost and weight, are often offset by its many advantages, and it remains an excellent choice for numerous types of mechanical applications.
Make Copper Parts With Fictiv
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Whether you’re working on prototypes or full-scale production, Fictiv ensures your parts arrive on time, to spec, and with full quality assurance. Get started today—upload your design, and we’ll provide a quote within 24 hours.