Custom Cut & Weld Solutions for Flexible Copper Strand Connectors

A flexible copper stranded connection is a highly conductive and flexible component made by precision-twisting high-purity copper wires (typically T1/T2 red copper, ≥99.9% purity) into circular or rectangular shapes. It features excellent flexibility, bend resistance, and reliable conductivity, ideal for dynamic, confined, or vibration-prone applications. It can be precisely cut and welded to terminals, busbars, or other conductive parts, ensuring secure, low-resistance, and durable connections while retaining flexibility and mechanical strength.

Product Description

Structural Composition

Conductor High-purity electrolytic copper wire (T1/T2 red copper, ≥99.9% purity).
Structure Precision-twisted multi-strand fine copper wires (0.05–0.3 mm), forming circular, rectangular, or custom cross-sections. Compact, flexible, and highly tensile.
Surface Treatment (Optional) Bare, tin-plated, or silver-plated for enhanced oxidation resistance, corrosion resistance, and weldability.
Protection (Optional) PVC/silicone insulation or metal shielding for insulation, EMI resistance, or high-temp performance.

Key Features

High Flexibility: Twisted structure enables tight bending and vibration resistance.
Excellent Conductivity: Low resistance for stable high-current/signaling.
Mechanical Strength: Withstands tension, compression, and fatigue.
Fatigue Resistance: Reliable under repeated motion.

Applications

Power systems, rail traction, automation/robotics, welding/electrolysis equipment, marine engineering, new energy (PV/wind), and building/construction (slip rings, lighting).

Product Specifications

Nominal CSA mm² Calculated Area mm² Structure Nominal Outer Diameter
Total Wires Strands * Wires * Cores / Wire Dia.
0.650.6593366*56/0.051.2
0.750.7653906*65/0.051.4
1.000.9895047*72/0.051.7
1.501.4847567*108/0.052.1
2.502.30711767*3*56/0.052.3
3.002.96715127*3*72/0.052.5
4.003.956201612*3*56/0.052.8
5.004.946252015*3*56/0.053.1
6.006.264319219*3*56/0.053.5
8.008.054410419*3*72/0.054
10.0010.067513019*3*90/0.054.6
1.501.4802037*29/0.11.8
2.001.9792527*36/0.12.2
2.502.5303227*46/0.12.4
4.003.9605047*72/0.12.8
10.008.890126012*105/0.14.8
16.0016.014204015*136/0.16.2
25.0025.05731927*3*152/0.18
50.0049.013277515*5*37/0.1512

* Cross-sectional area and monofilament diameter are tailored to customer needs (0.05mm—0.15mm). Length is precision-cut as per drawings.

Frequently Asked Questions
Q: What is the purity level of the copper used?
A: We use high-purity electrolytic copper (T1/T2 red copper) with a purity level of ≥99.9%, ensuring maximum conductivity and reliability.
Q: Can the surface of the copper wire be treated for corrosion?
A: Yes, optional surface treatments include tin-plating and silver-plating, which provide excellent oxidation and corrosion resistance.
Q: What insulation materials are available for these conductors?
A: We offer several protection options, including PVC and silicone insulation, as well as metal shielding for EMI resistance and high-temperature environments.
Q: Is it possible to customize the cross-sectional area?
A: Absolutely. The cross-sectional area and monofilament diameter (ranging from 0.05mm to 0.15mm) can be fully customized according to your technical requirements.
Q: Are these products suitable for robotics and moving parts?
A: Yes, the precision-twisted multi-strand structure provides high flexibility and fatigue resistance, making them ideal for robotics and automation systems involving repeated motion.
Q: How do you ensure the precision of the wire length?
A: All wires are precision-cut according to specific customer drawings or provided technical specifications to ensure a perfect fit for your application.

Related Products