Copper Braid Manufacturing Process

Copper Wire Drawing: The process begins with high-purity copper rods. These rods are drawn through a series of progressively smaller dies to create fine copper wires of the desired diameter. The diameter of these wires will influence the flexibility and current-carrying capacity of the final braid.
Annealing: After drawing, the copper wires are often annealed. This heat treatment process softens the copper, increases its ductility and flexibility, and relieves internal stresses introduced during the drawing process.
Tinning or Coating (Optional): In some applications, the individual copper wires may be tinned (coated with a thin layer of tin) or coated with other materials like nickel or silver. This improves solderability and corrosion resistance.

Loading the Braiding Machine: The fine copper wires are wound onto bobbins, which are then loaded onto a braiding machine. These machines come in various types (horizontal, vertical, circular) and configurations depending on the desired braid structure and production volume.
Interlacing the Wires: The braiding machine interlaces the copper wires in a specific pattern. This is achieved through a system of rotating carriers that move the bobbins, causing the wires to cross over and under each other.
Braid Structure: The structure of the braid can vary depending on the application. Common types include:
Flat Braid: Wires are braided to create a flat, ribbon-like structure, offering flexibility in two axes.
Round Braid: Wires are braided in a circular fashion, providing flexibility in three axes.
Rope Braid: A more complex braid offering maximum flexibility.
Tubular Braid (Shielding Braid): Braided into a tube to shield cables from electromagnetic interference.
Pitch and Density: The braiding machine controls the pitch (the angle and distance between the interlacing points) and the density (the number of wires per unit width or diameter), which affect the braid's flexibility, strength, and conductivity

For flat braid, the initially tubular braid is often passed through rollers to flatten it into the desired shape and thickness.

In many applications, the copper braid needs to be terminated for connection. This can involve:
Crimping: Attaching terminals or lugs to the ends of the braid using high-pressure crimping tools.
Soldering or Brazing: Soldering or brazing the braid ends to connectors or components.
Welding: Welding the braid to other metal parts.
Cold Pressing: Compacting the braid ends into a solid copper ferrule for connection.

Throughout the manufacturing process, quality checks are performed to ensure the braid meets specifications regarding dimensions, conductivity, tensile strength, and finish.

The finished copper braid is wound onto spools or cut to specific lengths and packaged for shipment.