Comprehensive Overview of Copper Inserts and Copper Threaded Inserts
We are one of the leading manufacturers and exporters of Copper Inserts and Copper Threaded Inserts from India. We have been supplying precision copper threaded inserts, copper heat-set inserts, copper press-fit inserts, and copper hardware to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing high-quality copper inserts using advanced CNC machining technology, precision thread rolling processes, cold forming operations, knurling equipment, and comprehensive surface treatment capabilities. With over three decades of global experience in copper insert manufacturing, we serve diverse industries including electronics copper inserts for PCB mounting, automotive copper threaded inserts for plastic components, electrical copper inserts for terminal blocks, furniture copper inserts for wood assembly, aerospace copper inserts for composite materials, medical device copper inserts for equipment housings, telecommunications copper inserts for equipment enclosures, industrial machinery copper inserts for plastic and composite parts, and consumer products copper inserts for appliance assembly. Our expertise encompasses working with various copper grades including pure Copper C11000 inserts offering excellent electrical conductivity and thermal management, Silicon Bronze inserts for marine applications, Brass inserts for decorative applications, Phosphor Bronze inserts for wear resistance, and Beryllium Copper inserts for high-strength requirements. We manufacture copper inserts ranging from small M2 threaded inserts for electronics to large M12 inserts for industrial applications, all maintaining superior thread quality, precise external dimensions, excellent pull-out resistance, and reliable long-term performance in diverse host materials including plastics, composites, wood, and soft metals.
Our advanced manufacturing capabilities in producing precision copper threaded inserts extend across multiple manufacturing processes including CNC Swiss-type automatic turning for small diameter inserts with tight tolerances, multi-spindle automatic screw machines for high-volume production, thread rolling equipment creating precise internal threads with work-hardened surfaces, thread cutting on CNC lathes for specialty thread forms, knurling operations creating external engagement features including diamond knurl, straight knurl, and helical knurl patterns, slotting operations for installation slots in heat-set and ultrasonic inserts, external thread rolling for self-tapping inserts, and surface treatment including tin plating, nickel plating, or passivation. Our engineering team possesses deep technical knowledge of copper material properties, insert design parameters, installation methods including heat-setting, ultrasonic insertion, press-fitting, and self-tapping installation, pull-out force calculations, torque-out resistance optimization, and host material compatibility ensuring every copper insert meets or exceeds customer specifications and application requirements. Our quality management system complies with ISO 9001:2015 standards, automotive quality standards including IATF 16949, international fastener standards, customer-specific insert requirements, and industry standards for electronics, medical devices, and aerospace applications. We maintain complete traceability of copper raw material certificates, detailed manufacturing process documentation, dimensional inspection records, mechanical test results including pull-out and torque-out testing, and material test reports for every batch of copper inserts produced. Our customers across North America, European Union countries, United Kingdom, Australia, Middle East regions, and Southeast Asian markets trust our copper insert expertise for their critical assembly and fastening applications.
Copper Inserts – Threaded Fastening Solutions for Soft Materials
Copper Inserts represent specialized threaded fastening components designed to provide strong reliable threads in soft materials including thermoplastics, thermosets, composites, wood, and soft metals where direct tapping would result in weak threads with poor pull-out resistance and limited reusability. These copper inserts are manufactured with precision internal threads accepting standard machine screws or bolts, external engagement features securing insert in host material through various mechanisms, and copper construction providing excellent electrical conductivity, thermal management, non-magnetic properties, and corrosion resistance. Copper inserts find extensive applications in electronics PCB mounting providing threaded attachment points for components and enclosures, automotive plastic component assembly including interior trim, electrical housings, and under-hood components, electrical equipment manufacturing establishing grounding connections and terminal mounting points, furniture assembly providing durable threads in wood and engineered wood products, aerospace composite structures offering lightweight threaded fastening in carbon fiber and fiberglass, medical device housings creating sterile threaded connections in plastic enclosures, telecommunications equipment enclosures providing EMI shielding with threaded mounting, industrial machinery plastic housings and covers requiring repeated assembly and disassembly, consumer appliances establishing durable fastening in plastic components, and musical instrument construction providing threaded hardware mounting in wood. The design of copper inserts incorporates internal thread specifications matching standard machine screw threads, external features including knurling, threads, or expansion mechanisms securing insert in host material, overall length appropriate for material thickness and load requirements, wall thickness providing thread strength, and installation features facilitating proper insert placement.
Our copper insert manufacturing services include engineering consultation for insert selection based on host material, load requirements, and installation method, material recommendation considering electrical conductivity, thermal properties, and environmental conditions, custom insert design for non-standard thread sizes or unique applications, prototype development with installation and performance validation, high-volume production with consistent thread quality and dimensional accuracy, various insert types including heat-set, ultrasonic, press-fit, self-tapping, and expansion inserts, thread sizes from M2 to M12 metric and #2 to 1/2″ unified inch threads, external configurations including diamond knurl, straight knurl, helical threads, and smooth press-fit, surface treatment including tin plating or bare copper, and complete documentation with material certificates and mechanical test reports. We accommodate copper insert lengths from 3mm to 30mm, external diameters from 3mm to 20mm, thread depths from 2mm to 25mm, and wall thicknesses from 0.5mm to 3mm depending on thread size and strength requirements. Material specifications conform to ASTM B124 for copper bars and rods, ASTM B152 for copper sheet and plate, and corresponding international standards including EN designations for European copper grades, JIS specifications for Japanese copper standards, and IS standards for Indian copper materials. The lead time for copper insert production typically ranges from four to six weeks depending on insert size, thread specifications, quantity, external feature complexity, and surface treatment requirements.
Copper Threaded Inserts – Heat-Set, Ultrasonic, and Press-Fit Types
Copper Threaded Inserts represent the specific category of copper inserts featuring precision internal machine screw threads and various external configurations optimized for different installation methods and host materials. These precision copper threaded inserts are manufactured in multiple configurations including heat-set inserts with diamond or straight knurl exterior installed using heated insertion tools melting thermoplastic creating mechanical lock upon cooling, ultrasonic inserts with specialized knurl patterns installed using ultrasonic insertion equipment vibrating insert into thermoplastic, press-fit inserts with smooth or lightly knurled exterior installed using arbor press or hydraulic press creating interference fit, self-tapping inserts with external threads cutting into host material during installation, expansion inserts with slotted barrel expanding radially when screw is installed, and molded-in inserts placed in mold before plastic injection. Common copper threaded insert styles include symmetrical inserts with knurling and internal threads centered, flush-head inserts with enlarged top flange sitting flush with surface, through-hole inserts with continuous thread allowing screw to pass completely through, blind inserts with closed bottom end, undercut inserts with retention features preventing rotation, and flanged inserts with integral washer surface distributing load.
The manufacturing process for precision copper threaded inserts begins with copper bar stock or wire selection in appropriate diameter to accommodate final external dimension and internal thread, CNC Swiss-type automatic turning or multi-spindle screw machines creating overall dimensions and internal bore, thread rolling using planetary thread rollers or thread whirling for internal threads producing accurate thread form with work-hardened surface improving strength and wear resistance, thread cutting on CNC lathes for specialty threads or small quantities, external knurling operations creating diamond pattern typically 30-33 TPI, straight knurl, or helical knurl using knurling wheels with controlled depth 0.15-0.30mm, slotting operations for heat-set and ultrasonic inserts creating installation slots facilitating insertion tool engagement, external thread rolling for self-tapping inserts, chamfering operations on both ends facilitating installation and screw engagement, deburring removing sharp edges, surface finishing, tin plating or other surface treatment if specified, quality inspection verifying thread quality using thread gauges, external dimension verification, knurl depth measurement, and mechanical testing including pull-out force validation. Our copper threaded insert capabilities include thread sizes M2 to M12 metric with standard 0.4mm to 1.75mm pitch, unified inch threads #2 to 1/2″ with coarse or fine pitch, internal thread lengths from 2mm to 25mm, external diameters from 3mm to 20mm, overall lengths from 3mm to 30mm, knurl depths 0.15-0.30mm, and tolerances maintaining thread class 6H or better with external dimensions ±0.05mm.
Copper Material Grades and Specifications
Copper Material Specifications and Standards for Inserts
| Copper Grade | International Designation | Key Properties | Typical Applications | Standards |
|---|---|---|---|---|
| Copper C11000 | CW004A (EN), C1100 (JIS), T2 (GB) | 99.9% pure copper, excellent conductivity, good machinability | Electronics, electrical, thermal management inserts | ASTM B124, BS EN 1652, DIN EN 13601, JIS H3250, IS 191 |
| Silicon Bronze C65500 | CW115C (EN), CAC406 (JIS) | High strength, excellent marine corrosion resistance | Marine applications, outdoor equipment inserts | ASTM B98, BS EN 12163, JIS H3250 |
| Brass C36000 | CW614N (EN), C3604 (JIS) | Free-machining, decorative, good strength | Furniture, decorative, general purpose inserts | ASTM B16, BS EN 12164, JIS H3250 |
| Phosphor Bronze C51000 | CW450K (EN), C5191 (JIS) | Wear resistant, spring properties, corrosion resistant | High-cycle applications, wear resistance inserts | ASTM B103, BS EN 12166, JIS H3110 |
| Beryllium Copper C17200 | CW101C (EN), C1720 (JIS) | Highest strength, heat treatable, non-magnetic | High-strength, aerospace, specialized inserts | ASTM B194, BS EN 12166, JIS H3270 |
Copper Threaded Insert Material Properties
| Property | C11000 Copper | Silicon Bronze | Brass C36000 | Phosphor Bronze | Beryllium Copper |
|---|---|---|---|---|---|
| Tensile Strength (MPa) | 220-260 | 380-520 | 340-470 | 410-620 | 1170-1310 (HT) |
| Hardness (HB) | 45-65 | 70-90 | 60-100 | 80-150 | 320-380 (HT) |
| Electrical Conductivity (% IACS) | 100% | 7% | 28% | 15% | 22% |
| Thermal Conductivity (W/m·K) | 391 | 42 | 115 | 50 | 105 |
| Machinability Rating | Good | Excellent | Excellent | Good | Good |
| Pull-Out Resistance | Good | Excellent | Good | Excellent | Excellent |
| Cost Factor | Standard | Medium | Low | Medium | Very High |
Manufacturing Processes and Technology
Our precision copper threaded insert manufacturing facility employs multiple manufacturing processes including CNC Swiss-type automatic lathes with guide bushing support producing small diameter inserts with excellent concentricity and tight tolerances, multi-spindle automatic screw machines for high-volume production of standard insert configurations, single-spindle CNC turning centers for custom inserts and prototypes, planetary thread rolling machines creating internal threads with superior strength compared to cut threads, thread whirling for internal threads in long inserts, CNC thread cutting for specialty thread forms, rotary knurling equipment creating diamond and straight knurl patterns with controlled depth, slotting machines for heat-set and ultrasonic insert installation slots, external thread rolling for self-tapping inserts, and surface treatment facilities including electroplating and passivation.
Manufacturing Process Flow: Copper wire or bar stock procurement and inspection → CNC turning external dimensions and internal bore → Internal thread rolling or cutting → External knurling or thread forming → Slotting if required → Chamfering both ends → Deburring operations → Surface treatment if specified → Quality inspection including thread verification → Mechanical testing on samples → Packaging with specifications → Final shipment.
Copper Threaded Insert Types and Specifications
Standard Copper Threaded Insert Dimensions
| Thread Size | External Diameter (mm) | Overall Length (mm) | Thread Depth (mm) | Knurl Type | Installation Method |
|---|---|---|---|---|---|
| M2 x 0.4 | 3.2 | 3-6 | 2-4 | Diamond, Straight | Heat-set, Ultrasonic |
| M2.5 x 0.45 | 3.8 | 3-8 | 2-6 | Diamond, Straight | Heat-set, Ultrasonic |
| M3 x 0.5 | 4.6 | 4-10 | 3-8 | Diamond, Straight, Helical | Heat-set, Ultrasonic, Press-fit |
| M4 x 0.7 | 6.0 | 5-12 | 4-10 | Diamond, Straight, Helical | Heat-set, Ultrasonic, Press-fit |
| M5 x 0.8 | 7.2 | 6-15 | 5-12 | Diamond, Straight, Helical | Heat-set, Ultrasonic, Press-fit |
| M6 x 1.0 | 8.5 | 8-20 | 6-16 | Diamond, Helical | Heat-set, Press-fit, Self-tapping |
| M8 x 1.25 | 11.0 | 10-25 | 8-20 | Diamond, Helical | Press-fit, Self-tapping |
| M10 x 1.5 | 13.5 | 12-30 | 10-25 | Helical | Press-fit, Self-tapping |
Copper Insert Installation Methods
| Installation Method | Description | Suitable Materials | Advantages |
|---|---|---|---|
| Heat-Set | Insert heated and pressed into undersized hole | Thermoplastics (ABS, PC, Nylon, PVC) | High pull-out strength, flush installation |
| Ultrasonic | Ultrasonic vibration melts plastic during insertion | Thermoplastics | Fast installation, strong bond, no external heat |
| Press-Fit | Insert pressed into sized hole creating interference | Plastics, wood, soft metals | Simple tooling, no heat, reversible |
| Self-Tapping | External threads cut into material during installation | Thermoplastics, thermosets, wood | No pre-installation required, field installation |
| Molded-In | Insert placed in mold before injection or casting | All plastics | Strongest bond, production efficiency |
| Expansion | Slotted insert expands when screw installed | Wood, particle board, soft materials | Simple installation, good load distribution |
Quality Control and Testing
Thread Quality Inspection: Every batch of copper threaded inserts undergoes comprehensive thread inspection using thread ring gauges verifying internal thread pitch diameter, major diameter, and minor diameter conforming to 6H tolerance class or as specified, thread profile verification using optical comparators or thread micrometers, thread depth measurement, and functional testing threading sample screws verifying smooth engagement and proper fit.
Dimensional Inspection: External diameter measurement using precision micrometers verifying dimensions within ±0.05mm tolerance, overall length verification, wall thickness measurement ensuring adequate thread strength, knurl depth measurement using depth micrometers confirming 0.15-0.30mm engagement depth, slot width and depth verification for heat-set and ultrasonic inserts, and chamfer inspection ensuring proper lead-in for screws and installation tooling.
Mechanical Testing: Pull-out force testing measures force required to extract installed insert from host material sample validating minimum pull-out strength typically 200-500N depending on insert size and host material, torque-out testing evaluates rotational resistance preventing insert spinning in host material, thread strip strength testing validates internal thread load capacity, and installation force measurement characterizes forces required for proper insert placement.
Material Verification: Chemical composition analysis using optical emission spectroscopy confirms copper grade matches material certification. Hardness testing validates material condition appropriate for application. Material certificates from copper supplier document chemical analysis and mechanical properties.
Documentation: Complete documentation includes material certificates from copper supplier with chemical analysis, dimensional inspection reports with thread verification results, mechanical test reports including pull-out force data, installation guidelines with recommended hole sizes and procedures, and certificate of conformance stating compliance with specifications.
Industries and Applications
Electronics Industry: Copper threaded inserts for PCB mounting providing grounded threaded attachment points, electronic enclosure assembly with thermal management through copper heat dissipation, electrical component mounting, EMI shielding applications utilizing copper conductivity, and consumer electronics housing assembly.
Automotive Industry: Plastic component assembly including interior trim panels, electrical housing mounting, under-hood component assembly requiring heat resistance, battery mounting systems, sensor housings, and automotive lighting assemblies utilizing copper threaded inserts for secure attachment.
Electrical Equipment: Terminal block assembly using copper inserts for electrical connections, electrical enclosure mounting, switch and relay housings, distribution panel components, grounding connections utilizing copper conductivity, and power supply enclosures.
Furniture Industry: Wood furniture assembly using copper threaded inserts in solid wood and engineered wood, cabinet hardware mounting, office furniture component assembly, upholstered furniture frames, and decorative furniture utilizing brass inserts for aesthetic appeal.
Aerospace Industry: Composite structure assembly using copper inserts in carbon fiber and fiberglass, aircraft interior component mounting, avionics housing assembly, lightweight structural assemblies, and satellite component mounting utilizing non-magnetic copper inserts.
Medical Devices: Medical equipment housing assembly requiring sterilization compatibility, diagnostic equipment enclosures, surgical instrument handles, patient monitoring equipment, dental equipment components, and laboratory instrument assembly.
Telecommunications: Equipment enclosure assembly using copper inserts for EMI shielding and grounding, antenna mounting hardware, telecommunications shelter equipment, server rack components, and cable management hardware.
Industrial Machinery: Plastic machinery guards and covers, control panel assembly, pneumatic and hydraulic component housings, industrial automation equipment, sensor housings, and process equipment utilizing copper threaded inserts for repeated assembly and disassembly.
Performance Specifications
Copper Threaded Insert Performance Parameters
| Parameter | Small Inserts (M2-M4) | Medium Inserts (M5-M8) | Large Inserts (M10-M12) |
|---|---|---|---|
| Thread Size Range | M2 – M4 | M5 – M8 | M10 – M12 |
| External Diameter | 3.2 – 6.0 mm | 7.2 – 11.0 mm | 13.5 – 18.0 mm |
| Overall Length | 3 – 12 mm | 6 – 25 mm | 12 – 30 mm |
| Pull-Out Force (ABS) | 100 – 300 N | 300 – 800 N | 800 – 1500 N |
| Torque-Out Resistance | 0.5 – 1.5 Nm | 2 – 5 Nm | 5 – 10 Nm |
| Thread Class | 6H | 6H | 6H |
| Knurl Depth | 0.15 – 0.25 mm | 0.20 – 0.30 mm | 0.25 – 0.35 mm |
| Installation Temperature | 200-260°C | 200-260°C | 200-260°C |
Frequently Asked Questions
Q1: What are the advantages of copper threaded inserts over brass inserts?
Copper threaded inserts provide superior electrical conductivity 100% IACS compared to brass 28% IACS making them ideal for grounding and electrical applications, excellent thermal conductivity 391 W/m·K for heat dissipation applications, non-magnetic properties for sensitive electronics and instrumentation, and good corrosion resistance. Brass inserts offer higher strength and lower cost. Material selection depends on whether electrical conductivity, thermal management, or mechanical strength is priority.
Q2: How do I determine the correct hole size for copper insert installation?
For heat-set inserts in thermoplastics, hole diameter should be external insert diameter minus knurl depth minus 0.1-0.2mm creating interference fit. For ultrasonic inserts, hole diameter typically equals external diameter minus 0.15-0.25mm. For press-fit inserts, hole diameter creates 0.05-0.15mm interference. Consult manufacturer specifications or conduct testing with sample material as optimal hole size varies with plastic type, temperature, and application requirements.
Q3: What is the typical lead time for copper threaded insert orders?
Standard lead time is four to six weeks from purchase order confirmation to shipment, accounting for copper material procurement, CNC turning operations, thread rolling or cutting, knurling operations, slotting if required, surface treatment if specified, quality inspection including thread verification, mechanical testing, and packaging. For standard metric sizes with materials in stock, expedited delivery within 2-3 weeks may be possible.
Q4: Can copper inserts be installed in thermoset plastics?
Yes, copper inserts can be installed in thermoset plastics including phenolics, epoxies, and polyesters using ultrasonic, press-fit, or self-tapping methods. Heat-set installation is not suitable for thermosets as these materials do not melt upon heating. Self-tapping inserts with external threads work well in thermosets cutting threads during installation. Press-fit inserts with appropriate knurl patterns also provide good retention in rigid thermosets.
Q5: What documentation is provided with copper threaded insert shipments?
We provide comprehensive documentation including material certificates from copper supplier with chemical analysis, dimensional inspection reports with thread verification data, mechanical test reports including pull-out force and torque-out measurements for representative samples, installation guidelines with recommended hole sizes and installation parameters, technical drawings showing insert dimensions and specifications, certificate of conformance stating compliance with purchase order requirements, and traceability documentation linking production batches to material certifications.
Why Choose Our Copper Threaded Insert Services
Three Decades of Insert Manufacturing Excellence: With over 30 years of copper insert manufacturing experience serving electronics, automotive, electrical equipment, furniture, aerospace, and medical device industries across global markets, we have developed deep expertise in threaded insert design, CNC machining processes, thread rolling technology, and application engineering.
Comprehensive Product Range: We manufacture complete range of copper threaded inserts including heat-set, ultrasonic, press-fit, self-tapping, and molded-in types, accommodating thread sizes M2 to M12 metric and #2 to 1/2″ unified, various external configurations including diamond knurl, straight knurl, and helical threads, and multiple copper grades for different application requirements.
Advanced Manufacturing Technology: Our CNC Swiss-type automatic lathes and multi-spindle screw machines enable high-precision production with tight tolerances, planetary thread rolling equipment creates strong accurate internal threads, automated knurling operations ensure consistent engagement features, and comprehensive quality control systems verify every insert meets specifications.
Multiple Copper Grade Options: We manufacture copper threaded inserts from pure copper C11000 for electrical and thermal applications, Silicon Bronze for marine environments, Brass for decorative and general purpose applications, Phosphor Bronze for wear resistance, and Beryllium Copper for high-strength specialized requirements.
Quality Assurance and Testing: Every batch undergoes thread verification using precision gauges, dimensional inspection, mechanical testing including pull-out and torque-out validation on representative samples, material verification through chemical analysis, and complete documentation providing performance data and conformance certification.
Engineering Support Services: Our experienced engineering team provides insert selection guidance based on host material and load requirements, hole size recommendations for various installation methods, custom insert design for unique applications, installation method optimization, pull-out force calculations, and technical consultation for assembly process development.
Competitive Manufacturing Advantage: Manufacturing in India provides significant cost advantages allowing us to offer copper threaded insert products typically 30-40% lower cost than North American or European manufacturers without compromising quality standards, dimensional accuracy, thread quality, or material specifications.
International Standards Compliance: Our copper threaded inserts conform to international fastener standards, thread specifications per ISO and ANSI, customer engineering drawings and specifications, and industry-specific requirements for electronics, automotive, aerospace, and medical device applications.
Glossary of Technical Terms
Threaded Insert: Metal component with internal threads installed in host material providing durable reusable threads.
Heat-Set Insert: Threaded insert with knurled exterior installed by heating and pressing into thermoplastic.
Ultrasonic Insert: Threaded insert installed using ultrasonic vibration melting thermoplastic during insertion.
Press-Fit Insert: Threaded insert installed by pressing into sized hole creating interference fit.
Self-Tapping Insert: Threaded insert with external threads cutting into host material during installation.
Knurling: Textured pattern rolled into metal surface creating mechanical engagement, measured in teeth per inch (TPI).
Diamond Knurl: Knurl pattern with crossed diagonal lines creating diamond shape.
Pull-Out Force: Force required to extract installed insert from host material.
Torque-Out: Rotational resistance preventing insert from spinning in host material.
Thread Rolling: Manufacturing process creating threads by displacing material using dies, stronger than cut threads.
6H Thread Class: Internal thread tolerance class per ISO standards indicating medium fit.
IACS: International Annealed Copper Standard reference for electrical conductivity where pure copper equals 100%.
Call to Action – Contact Us Today
Ready to discuss your copper threaded insert requirements? Our experienced team is here to help you with precision copper inserts for your electronics, automotive, electrical, and industrial applications.
Request a Quote: Send us your technical specifications, thread sizes, and quantity requirements to sales@jambrass.com for a detailed quotation within 24 hours.
Call Us Directly: Speak with our technical sales team at +91-22-43449300 / +91-22-43449323 during business hours (Monday-Saturday, 9:00 AM – 6:00 PM IST) to discuss your copper threaded insert requirements.
Visit Our Offices:
Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat, India – 361004
Contact Person: Mr. Mehul Vora
Quality Documentation: Request sample certificates of conformance, material test reports, mechanical test results, and installation guidelines by contacting sales@jambrass.com
