Technical Data Sheet: C1100 Copper Alloys for Rapid Prototyping & Sheet Metal Fabrication

1.0 Executive Summary

This document provides a technical comparison of three common tempers of C1100 (ETP Copper) —H00 (Soft), H02 (Half-Hard), and H04 (Hard)—within the context of rapid prototyping and sheet metal fabrication. The selection of temper is a critical design decision that directly impacts the prototype's formability, structural integrity, and functional performance. This guide outlines their distinct properties, ideal use cases, and provides key considerations for sheet metal processing and available surface treatments.

2.0 Material Overview: C1100 Copper

C1100, also known as Electrolytic Tough Pitch (ETP) copper, is a commercially pure copper (99.90% min). It is prized for its excellent electrical and thermal conductivity, corrosion resistance, and antimicrobial properties. Its temper is mechanically altered through cold working (e.g., rolling) to achieve a range of strength and hardness levels from soft and formable to hard and spring-like.

3.0 Comparison of C1100 Tempers in Rapid Prototyping

The choice between H00, H02, and H04 is a balance between formability and strength.

3.1 Typical Use Environments

• C1100 H00 (Soft/Annealed) is ideal for:

• Prototypes requiring extreme deformation: deep drawing, severe stretching, spinning, or complex stamped shapes.

• Creating prototypes for plumbing components, vessels, or artistic features where intricate shapes are needed.

• Applications where the part will be subsequently work-hardened during use.

• PuKong Recommendation: The default choice for the most complex forming operations where risk of cracking must be eliminated.

• C1100 H02 (Half-Hard) is ideal for:

• Prototypes requiring a balance of strength and formability. It is the most versatile temper for general-purpose prototyping.

• Electrical brackets, shields, and housings that require multiple bends but must maintain structural rigidity.

• Applications where the final product will be in a half-hard state. It is often the "sweet spot" for many functional prototypes.

• PuKong Recommendation: The best starting point for most projects requiring bending and moderate forming.

• C1100 H04 (Hard) is ideal for:

• Prototypes that must function as springs, electrical contacts, or stiff structural members.

• Components that require high yield strength to resist deformation under load, such as brackets for heavy components.

• Simple, high-strength shapes where minimal forming (e.g., a single, gentle bend) is required.

• Applications mimicking the final product's high strength and spring-back characteristics.

4.0 Sheet Metal Fabrication Considerations

• Bending and Forming:

• H00: Can be bent to very tight radii. Excellent for complex shapes. Minimal springback, making bend angle prediction accurate.

• H02: Requires a larger bend radius than H00. Exhibits noticeable springback that must be compensated for in tooling and bend calculations.

• H04: Requires a much larger minimum bend radius to avoid cracking. Exhibits significant springback. Not suitable for complex forming.

• Blankling and Piercing:

• Softer tempers (H00) are more prone to burring and can gall onto tooling. Harder tempers (H04) require more force and can wear tools faster.

• Solution: Ensure all punches and dies are razor-sharp. Use appropriate die clearances (typically 5-8% per side for copper).

• Work Hardening:

• H00 material will rapidly work-harden during forming. This may require annealing between deep drawing or multi-stage forming operations to restore ductility and prevent cracking.

• H02 and H04 are already work-hardened and are less susceptible to further hardening during fabrication.

• Handling and Machining:

• Copper is soft and marks easily. Always use soft jaws (e.g., aluminum, nylon) in vises and clamps to prevent surface damage and marring.

• All tempers are gummy and can be challenging to machine. Use sharp, positive-rake tools, high speeds, and adequate coolant/lubrication for milling and turning.

5.0 Surface Finishing Options

Surface treatments enhance functionality, durability, and aesthetics.

• Nickel Plating:

• Purpose: Provides a hard, wear-resistant, and corrosion-resistant surface. Serves as an excellent diffusion barrier and undercoat for subsequent precious metal plating.

• Ideal for: RFI/EMI shielding enclosures, connectors, wear surfaces, and as a base for chrome or gold plating.

• Silver Plating:

• Purpose: Provides the highest electrical and thermal conductivity of any metal. Offers excellent solderability and high-temperature oxidation resistance.

• Ideal for: High-frequency RF components, waveguides, high-amp electrical contacts, and parts for high-temperature service.

• Tin Plating:

• Purpose: Excellent solderability, good corrosion resistance, and is a cost-effective alternative to silver.

• Ideal for: Busbars, electrical lugs, and components where reliable, low-resistance soldering is required.

• Electropolishing:

• Purpose: A electrochemical process that removes a thin surface layer. It deburrs, improves micro-finish, enhances natural aesthetics, and improves cleanliness.

• Note: Used for cosmetic appeal or for components requiring a very clean, smooth surface.

• Clear Lacquer / Chromate:

• Purpose: To prevent oxidation and tarnishing, preserving the natural copper color.

• Note: Less durable than plating; primarily used for decorative prototypes.

6.0 Conclusion

For PuKong Prototype, the strategic selection of C1100 temper is fundamental to project success.

• H00 is the choice for maximum formability.

• H02 is the versatile all-rounder for balanced properties.

• H04 is specified for high strength and spring applications.

By understanding these distinctions and adhering to specific sheet metal guidelines—particularly regarding bend radii, springback compensation, and tooling care—we can ensure efficient manufacturing and superior prototype quality. The available surface finishes allow us to further tailor the component's performance to meet exact electrical, mechanical, and environmental requirements, providing our clients with prototypes that are both form and function accurate.