Copper Inserts
Comprehensive Overview of High-Performance Copper Inserts
We are a specialized manufacturer and global supplier of precision Copper Inserts, engineered to provide durable, high-conductivity threaded solutions in plastic, composite, and rubber components. Our inserts leverage the exceptional thermal and electrical properties of high-purity copper alloys, including C11000 Electrolytic Tough Pitch Copper (ETP) for optimal conductivity and C10100 Oxygen-Free Copper for superior performance in critical applications. These inserts are designed to create permanent, reliable threads in soft materials where repeated assembly and disassembly would otherwise cause wear and failure. Our advanced manufacturing capabilities include CNC machining, cold heading, and precision knurling to produce inserts that meet the most demanding specifications for thermal management, electrical grounding, and structural integrity.
Copper Inserts – Superior Conductivity & Thermal Management
Copper Inserts are specialized threaded fasteners designed to be embedded into parent materials to provide a strong, wear-resistant thread. The high thermal and electrical conductivity of copper makes these inserts ideal for applications requiring heat dissipation, electrical grounding, or EMI/RFI shielding, in addition to robust mechanical fastening.
Applications of Copper Inserts
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Electronics Enclosures: Heat sink mounting, PCB fastening, and EMI shielding in plastic housings.
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Automotive Components: Sensor housings, connector blocks, and under-hood applications requiring thermal cycling resistance.
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Aerospace Systems: Avionics cooling, composite structure fastening, and electrical bonding.
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LED Lighting: Heat dissipation in LED housings and heat sink attachment.
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Telecommunications: RF components, antenna mounts, and equipment shielding.
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Medical Devices: Imaging equipment, diagnostic devices, and disposable medical tools.
Copper Alloy Specifications for Inserts
| Copper Alloy | UNS Designation | Key Properties | Typical Applications |
|---|---|---|---|
| C11000 ETP Copper | C11000 | Excellent electrical/thermal conductivity, good machinability | General purpose, electrical grounding, thermal management |
| C10100 OFC Copper | C10100 | Superior conductivity, excellent creep resistance | High-frequency RF, critical electronics, aerospace |
| C18200 Chromium Copper | C18200 | High strength, maintained conductivity at elevated temperatures | High-temperature applications, resistance welding fixtures |
Copper Insert Technical Specifications
| Parameter | C11000 (ETP Copper) | C10100 (OF Copper) | C18200 (Chromium Copper) |
|---|---|---|---|
| Electrical Conductivity (% IACS) | 101% | 102% | 80% |
| Thermal Conductivity (W/m·K) | 391 | 394 | 320 |
| Tensile Strength (MPa) | 220 – 360 | 220 – 380 | 380 – 480 |
| Yield Strength (MPa) | 69 | 70 | 275 |
| Thermal Expansion (10⁻⁶/K) | 17.0 | 17.0 | 17.2 |
Standard Sizes: M2 to M12, #2-56 to 1/2″-13 thread sizes.
Insert Types: Knurled, helical, ultrasonic, press-in, molded-in
Installation Methods: Thermal (Ultrasonic/Heat), Press-in, Molded-in
Standards: Custom OEM specifications, ISO 15480 (similar)
Product Range & Specifications
Knurled Copper Inserts
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Design: External knurls for 360° retention
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Installation: Press-in or ultrasonic installation
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Applications: General purpose plastic assemblies
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Benefits: Excellent pull-out and torque-out resistance
Helical Copper Inserts
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Design: Wire-formed coil for high-strength threads
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Installation: Threaded into pre-tapped holes
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Applications: Repairing stripped threads, enhancing thread life
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Benefits: Uniform stress distribution, compliance with thermal expansion
Ultrasonic Copper Inserts
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Design: Concentric knurls and lead-in chamfer
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Installation: Ultrasonic vibration embedding
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Applications: High-volume production environments
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Benefits: Fast installation, minimal stress on parent material
Molded-In Copper Inserts
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Design: Through-holes or undercuts for plastic flow
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Installation: Placed in mold before injection
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Applications: High-volume injection molding
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Benefits: Strongest bond with parent material
Manufacturing Processes & Quality Control
Our Copper Inserts are manufactured through precision-controlled processes:
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Material Selection: Certified copper alloy rod or wire
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CNC Machining: Precision turning of insert blanks
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Thread Cutting: Precision internal thread creation
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Knurling/Forming: External retention feature formation
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Heat Treatment: Stress relief or hardening (for C18200)
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Surface Finishing: Deburring and cleaning
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Quality Inspection: 100% dimensional and sample destructive testing
Quality Assurance Tests:
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Dimensional Verification: 100% check of OD, ID, length, and thread pitch
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Thread Gauging: Go/No-Go thread acceptance testing
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Knurl Pattern Inspection: Consistency and depth of retention features
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Pull-Out Force Testing: Mechanical strength in standard host materials
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Torque-Out Testing: Resistance to rotational forces
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Conductivity Testing: Electrical and thermal performance verification
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Material Certification: Mill Test Certificates for full traceability
Technical Data & Performance Specifications
Performance in Various Host Materials
| Host Material | Pull-Out Strength (N) | Torque-Out Strength (Ncm) | Recommended Insert Type |
|---|---|---|---|
| ABS Plastic | 1200 – 1800 | 400 – 600 | Knurled, Ultrasonic |
| Nylon 6/6 | 1500 – 2200 | 500 – 700 | Knurled, Molded-In |
| Polycarbonate | 1300 – 1900 | 450 – 650 | Helical, Ultrasonic |
| Aluminum | 2500 – 4000 | 800 – 1200 | Helical, Press-Fit |
| Die-Cast Zinc | 2200 – 3500 | 700 – 1000 | Helical, Knurled |
Thermal Performance Data
| Insert Size | Thermal Resistance (°C/W) | Heat Dissipation Capacity (W) |
|---|---|---|
| M3 | 18 – 22 | 2.5 – 3.0 |
| M4 | 14 – 18 | 3.5 – 4.5 |
| M5 | 11 – 14 | 5.0 – 6.5 |
| M6 | 8 – 11 | 7.0 – 9.0 |
Design Features & Benefits
Copper Insert Advantages
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Superior Thermal Management: Excellent heat dissipation from components to housings
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Electrical Conductivity: Ideal for grounding and EMI/RFI shielding applications
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Corrosion Resistance: Natural corrosion resistance in various environments
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Non-Magnetic Properties: Essential for sensitive electronic applications
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Long-Term Reliability: Maintains thread integrity through repeated cycles
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Ease of Installation: Compatible with standard installation equipment
Performance Characteristics
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High Pull-Out Strength: Excellent retention in parent materials
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Temperature Resistance: Suitable from -50°C to +200°C
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Thermal Cycling Performance: Compatible CTE with many plastics
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EMI Shielding Effectiveness: 60-100 dB attenuation depending on design
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Installation Speed: 1-3 seconds per insert in production environments
Frequently Asked Questions (FAQ)
Q1: Why choose copper inserts over stainless steel or brass?
Copper inserts provide superior thermal conductivity (8x better than stainless steel) and excellent electrical properties, making them ideal for applications requiring heat dissipation, electrical grounding, or EMI shielding. They’re also non-magnetic and offer better corrosion resistance than many alternatives.
Q2: What installation method is recommended for copper inserts?
The optimal installation method depends on production volume and parent material:
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Ultrasonic Installation: Best for high-volume production in thermoplastics
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Thermal Installation: Suitable for most thermoplastics with moderate volume
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Press-In Installation: Ideal for brittle materials or low-volume applications
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Molded-In Installation: Highest strength for injection molding applications
Q3: Can copper inserts be used in high-temperature applications?
Yes, copper inserts maintain their mechanical properties at elevated temperatures. Standard copper alloys are suitable for continuous service up to 200°C, while C18200 Chromium Copper can withstand temperatures up to 400°C while maintaining good conductivity.
Q4: Do you provide custom-designed copper inserts?
Absolutely. We specialize in custom insert manufacturing including special lengths, diameters, thread types, knurl patterns, and plating requirements. Our engineering team can optimize designs for your specific application and manufacturing process.
Q5: How does the thermal conductivity benefit my application?
Copper inserts act as thermal bridges, efficiently transferring heat from mounted components (like power semiconductors, LEDs, or processors) to heat sinks or enclosure surfaces. This can reduce operating temperatures by 15-30°C, significantly improving component reliability and lifespan.
Why Choose Our Copper Inserts?
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Material Expertise: Deep knowledge of copper metallurgy and alloy selection
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Precision Manufacturing: Advanced CNC machining and quality control
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Application Engineering: Technical support for design optimization
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Comprehensive Testing: Full mechanical and electrical performance validation
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Custom Solutions: Tailored designs for specific OEM requirements
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Quality Certification: ISO 9001:2015 certified manufacturing
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Global Supply: Reliable delivery to international markets
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Competitive Pricing: Cost-effective solutions without quality compromise
Call to Action – Contact Us Today
Enhance your product performance with our high-conductivity copper inserts. Contact us for quotations or technical assistance.
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Request a Quote: Email your specifications to sales@jambrass.com for prompt quotation
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Call Directly: +91-22-43449300 / +91-22-43449323 (Monday-Saturday, 9:00 AM – 6:00 PM IST)
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Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
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Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat – 361004
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Samples Available: Contact us for evaluation samples
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Technical Consultation: Our engineers are available for application support
We look forward to providing you with the highest quality copper inserts for your thermal management and electrical connectivity requirements.
