Stamped Copper Terminal Industry: Technology Iteration, Market Expansion And Sustainable Development

The manufacturing process of stamped copper terminals is mainly cold extrusion. Because its material (red copper) has low yield strength and high plasticity, it is suitable for efficient production through coreless cold extrusion technology. This process uses a combined mold structure to process the copper rod into a ring clamp, copper rod, flat head, and other structures in sequence and finally forms a long mounting hole. In recent years, laser welding technology has gradually been applied to copper terminal welding, especially in new energy vehicle battery modules. Blue light laser welding machines have significantly improved welding quality and efficiency with their high energy density and spatter-free characteristics.

In terms of materials, the research and development of high-conductivity copper alloys has become the focus of the industry. The conductivity of the new copper-chromium-zirconium alloy material is more than 15% higher than that of traditional products, while the corrosion resistance and mechanical strength are significantly improved. Copper Stamp is expected that the penetration rate of terminal products using this material will reach 30% in 2025. In addition, copper-aluminum composite terminals have been used in batches in energy storage projects by reducing material costs (reduced by 30%) and maintaining 90% conductivity.

The global Custom Metal Copper Stamped market is showing a steady growth trend. In 2025, the global stamped metal market is expected to grow from US$500.92 billion in 2024 to US$538.77 billion, of which the proportion of copper material applications continues to increase, mainly driven by demand for new energy vehicles, energy storage, communication equipment, and other fields. Specifically:

1. New energy vehicles: With the popularization of 48V architecture and the upgrade of high-voltage platforms, the demand for high-current Cross Copper Metal Stamping has surged. In 2024, the procurement volume of terminals with specifications above 300A for DC fast charging piles increased by 145% year-on-year, and it is expected that 600A terminals will enter the mass production stage in 2025.
2. Energy storage field: The demand for high-voltage and high-current Stamping Parts Copper Springs in energy storage systems drives technological innovation. For example, the new energy storage integrated copper tube bending terminal improves product consistency and stability by optimizing the stamping process.
3. Communications and data centers: The construction of 5G base stations and data centers is accelerating, and there is a strong demand for high-speed and high-frequency terminals. In 2025, high-speed I/O connectors with a single-channel rate of 112Gbps will usher in a volume increase, pushing the scale of the copper cable high-speed connector industry to exceed 10 billion yuan.
4. Industrial automation: The proportion of smart terminals with RFID identification functions will increase from 12% in 2022 to 37% in 2024, achieving full life cycle management.

1. Raw material price fluctuations: Copper prices are significantly affected by the global supply chain and geopolitics. The copper market is expected to grow by 7.8% in 2025, but we need to be vigilant about the impact of price fluctuations on the production costs of Copper Stamps.
2. Environmental protection requirements upgrade: The EU RoHS 3.0 amendment reduces the cadmium content limit from 100ppm to 50ppm, forcing companies to develop lead-free plating technology, such as tin-bismuth alloy alternatives.
3. Technology substitution risk: Aluminum terminals have increased their penetration rate in some fields due to their lightweight and cost advantages (weight reduction of 20%, cost reduction of 20%), and copper terminals need to consolidate their performance advantages through material innovation.