A flexible copper connector manufacturer needed more consistent end forming with less strand damage. HAIFEI developed a copper braid end compacting solution using material trials, dedicated locating dies and controlled forming conditions to address the customer’s production problems.
The Customer’s Forming Problem
The previous process produced uneven compaction, internal gaps, raised edges and inconsistent dimensions. Manual positioning also contributed to broken or loose strands, while production depended heavily on operator handling.
The customer wanted a repeatable process that improved end shape, reduced material damage and simplified operation.
How HAIFEI Developed the Solution
Trials with Different Braid Constructions
HAIFEI tested copper braids with different strand counts, wire diameters and thicknesses before refining the forming approach.
Dedicated Locating Dies
The solution used guided movement and customized dies with centered, symmetrical restraint to reduce braid displacement and uneven loading.
The forming sequence was developed around controlled pressure and travel rather than relying on manual positioning.
Integrated Processing
The project description covers loading, cutting, end forming and unloading, bringing the operations into a coordinated process.
Explore HAIFEI’s custom machine solutions for application-specific equipment.
Verification Before Acceptance
The customer reviewed the equipment during pre-acceptance, including continuous trial operation. Numerical dimensional results, cycle times and electrical test data are not published.
What Should Buyers Check on a Similar Project?
For a new copper braid forming application, define the finished end before selecting equipment. A drawing should identify the compacted region, required width and thickness, acceptable edge condition and the section that must remain flexible.
The following checks provide a useful basis for an agreed trial plan:
| Check |
What to Define |
| Finished dimensions |
Measurement positions and permitted variation |
| Strand condition |
Acceptance criteria for broken, loose or protruding wires |
| End shape |
Required profile, edge condition and flatness |
| Flexible transition |
Where compaction must stop and how the adjoining braid should behave |
| Subsequent assembly |
Fit with the actual mating component or next operation |
| Repeatability |
Sample quantity and inspection frequency during consecutive cycles |
These are suggested checks for future applications, rather than reported test results from this project.
Frequently Asked Questions
Q1.Is end compacting the same as crimping a terminal onto the braid?
The terms describe different operations. End compacting forms the braid itself, while terminal crimping attaches a separate terminal or sleeve. State which finished construction is required when requesting a quotation.
Q2.Can dimensional inspection confirm electrical performance?
Dimensional inspection confirms shape and size. If electrical performance is part of the product specification, define a separate test method and acceptance criteria for the finished connector.
Q3.What information is needed to evaluate another braid size?
Provide the braid construction, material condition, cross-sectional area, finished-end drawing and required output. Representative production samples help establish the appropriate tooling and trial scope.
Discuss Your Copper Braid Forming Requirements
Send HAIFEI your copper braid specifications, finished-part drawing and inspection requirements. Include any difficulties with positioning, loose strands, end dimensions or subsequent assembly.
Contact HAIFEI to discuss a copper braid forming trial and evaluate a configuration for your production requirements.
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