The Brief History of Copper

Copper is a versatile metal that has driven technology paradigm change for centuries. Copper is one of the most essential metals that allowed our civilization to reach the progress levels that were imaginable when first discovered, even though it was the first metal to be discovered by humankind. Copper helped humanity to have better tools for cooking, hunting, or fighting, and allowed humankind to reach the Moon, develop the electric car, to be connected with our smartphones no wonder where. No other metal probably has a more crucial paper on inhuman history shaping civilizations.

I. Prehistoric Era (~10,000 BC): Native Copper and Early Uses

Archaeological evidence suggests copper was first used around 10,000 years ago in the Middle East. During the prehistoric era, copper was one of the first metals used by humans, mainly in its native form - native copper, a naturally occurring metal, was shaped into very rudimentary tools, jewelry, or ornaments, including hunting gear and cooking utensils, transitioning from the use of rocks to the specialized use of copper ores.

• Example: In Çayönü, an ancient settlement in Turkey that dates from 9,500 – 6,500 BC, several small copper tools and beads have been discovered.

II. Copper Age (~5,000–3,000 BC): The Rise of Metallurgy

The Copper Age, also known as the Chalcolithic Period, marked the beginning of metallurgy. People began extracting the copper from ores and using it to create slightly more complex tools, weapons, and ornaments. In the early Copper Age, copper was shaped using a hammer. Then, the smelting technique was discovered, which made possible the production of purer copper and, therefore, the production as well as better quality tools with more complex geometries.

• Chemical Process: Smelting involves heating copper ore (Cu2O or Cu2S) with a reducing agent, such as carbon, to produce pure copper (Cu).
• Example: A copper axe was discovered next to the mummified body of Ötzi, a man who lived around 3300 BCE. The axe is made from nearly pure copper and has a wooden handle. It can be seen today in Italy's South Tyrol Museum of Archaeology, Bolzano.

III. Bronze Age (~3,300–1,200 BCE): The rise of Alloying

Copper was alloyed with tin to create bronze, a significantly stronger and more lasting metal, leading to the development of the Bronze Age, characterized by the widespread use of bronze in tools, weapons, and armor. Civilizations such as Mesopotamia, ancient Egypt, and the Indus Valley flourished during this era.

• Chemical Composition: Bronze is an alloy of copper (Cu) and tin (Sn), typically with a composition of 85-90% Cu and 10-15% Sn.
• Example: A Bronze Age sickle was discovered in the ancient city of Ur in modern Iraq. This artifact dates from 2,500 BC and currently can be found in the British Museum in London.

IV. Classical Antiquity (1,200 BC–500 AD): Copper Mining and Trade

During this period, more technical copper mining expanded. Major civilizations like the Greeks and Romans relied heavily on copper for coins, plumbing, and building materials, but also for the uses developed in previous civilizations, such as agricultural tools or weaponry and armory. Copper trade routes were established, especially across the Mediterranean, Anatolia, and the Balkans.

• Example: The Roman Empire's extensive use of copper in its plumbing systems, such as the famous Roman aqueducts, demonstrates copper's importance during this period.

V. Middle Ages (~500–1,500 AD): Copper Demand and Mining Techniques

The demand for copper and its alloys continued through the Middle Ages, especially to produce kitchen utensils, weaponry, bells, statues, and architectural elements. Copper mining and metallurgy techniques improved, particularly in Western Europe.

• Example: The magnificent copper roof of St. Mark's Basilica in Venice, Italy, is a testament to the enduring use of copper in architecture during this period.

VI. Industrial Revolution (18th–19th Century): Copper in Electricity and Telecommunications

The Industrial Revolution marked a drastic shift in human history, where technological innovation and rapid urbanization transformed society. Copper became essential during this industrial era, powering the rise and development of electricity and telecommunications. Copper's exceptional conductivity made it the ideal material for electrical wiring, bringing light to homes and enabling the operation of complex industrial systems. Copper also played a pivotal role in the burgeoning telecommunication networks, carrying voices across miles through telephone wires and connecting people in ways previously unimaginable. The emergence of copper stamping as a crucial process facilitated the production of a broad range of copper components essential for these new technologies.

• Example: The development of the telegraph, which relied heavily on copper wiring, revolutionized long-distance communication and marked a significant milestone in the history of copper.

VII. Modern Era (20th–21st Century): Copper in Electronics

The electrical industry, construction sector, electronics field, and green energy technologies rely heavily on it. It covers from power generation to electrical distribution, from internet networks to satellite communications. Copper use also extends to new mobility sectors, such as electric vehicles, and clean energy systems, such as solar panels and wind turbines.

How can copper applied in manufacturing process? 

The unique properties found in copper make it an ideal material for metal stamping. Metal stamping involves shaping and forming metal materials such as copper, aluminum, or stainless steel into desired shapes and designs, achieving very intricate geometries through a process that allows manufacturers to produce components with high accuracy, speed, and repeatability, and low defect rate, which is essential in industries such as electronics, automotive, and telecommunications to achieve mass production scale.

Layana is your one-stop partner for every stage of your metal stamped copper project. We handle everything—from design for manufacturing (DFM) and tooling fabrication to mass production and quality assurance—under one roof, saving you time and eliminating the hassle of coordinating with multiple vendors. Our integrated facilities house both a state-of-the-art tooling workshop and advanced mass production lines, operated by seasoned engineers who have crafted precise and complex progressive and transfer dies for world-class OEM companies. This expertise ensures high-quality production and innovative solutions tailored to your needs.

We also specialize in advanced bi-material processing, combining overmolding/insert molding with metal stamping. This increasingly popular technology reduces assembly steps, cuts costs, and improves material efficiency by enabling modular assembly of mechanical components—accelerating production without compromising on quality. Additionally, our in-house automation team scales projects seamlessly, supporting growth at every stage.

Copper Stamping Process Overview

I. Material Preparation

Copper sheets or blanks are selected based on the required thickness, hardness, and other specific attributes for the intended application. The copper blanks are fed into the tooling through a system that uncoils the rolled copper coil, flattens the strip, and positions it accurately for processing.

II. Die Setup

Copper stamping dies are categorized into single dies, compound or combination dies, and multi-station dies—further divided into progressive and transfer dies.
Stamping Process
In a progressive die setup, the copper sheet is fed into the die and subjected to controlled pressure, continuously moving through multiple stations to form complex parts in one automated process. In a transfer die setup, individual blanks or pre-formed parts are shifted between stations via mechanical or robotic handling systems.

III. Finishing

Post-stamping processes include deburring to remove excess material, machining (such as drilling, tapping, or milling) to achieve precise dimensions, and surface treatments like polishing and plating to enhance appearance, durability, and corrosion resistance.

Properties of Copper

1. High Conductivity

Copper’s ability to conduct both electricity and heat with remarkable efficiency makes it a cornerstone in industries from electronics to automotive. The next section delves into how copper’s unique combination of high conductivity, effective heat dissipation, and reliability supports innovation and efficiency across these sectors.

2. Corrosion Resistance

Copper forms a natural protective oxide layer that resists corrosion. While not immune to all corrosive agents, this property makes it suitable for use in environments that experience harsh conditions, such as marine, outdoor, or industrial applications.

3. Ductility

Copper's high ductility allows it to be drawn into thin wires or stamped into complex, intricate shapes without compromising its structural integrity. This property is especially vital for applications requiring precise, detailed components. Moreover, copper's ductility enhances fine blanking processes, enabling manufacturers to produce exceptionally accurate designs while minimizing material waste.

 
4. Strength

While copper is softer than many steels, it has a moderate tensile strength of around 210 MPa in its annealed state—enough for numerous structural, electrical, and plumbing applications. However, when extreme hardness or higher tensile strength is required, engineers often turn to copper alloys such as bronze, brass, or other metals.

5. Aesthetic Appeal

The distinctive reddish-orange hue of copper is prized in decorative and architectural designs. Copper is often used in visible applications, such as building facades and interior accents, where both its aesthetic and functional qualities are showcased.

The Applications of Copper Metal Stamping

• Electrical Components: Copper is widely used in the production of connectors, switches, contacts, battery tabs, and busbars, ensuring efficient power transfer and minimal energy loss in automotive, telecommunications, and consumer electronics.
• Thermal Management: Copper's high thermal conductivity makes it an ideal material for heat sinks, thermal interfaces, and cooling plates, which are crucial in LED lighting, computer processors, and other high-power devices to prevent overheating.
• Decorative and Architectural Features: Copper's attractive color and durability make it a popular choice for roofing, cladding, and ornamental details, providing both functional protection and aesthetic appeal in buildings and public structures.
• Mechanical Components: Copper's relatively high tensile strength makes it suitable for a range of mechanical components, including gears, bearings, and structural parts, ensuring reliable performance in industrial, automotive, and aerospace applications.

Common Copper Alloys That Used in Metal Stamping 

• C10100 (Oxygen-Free Electronic Copper)
  

  C10100 is a very high-purity copper alloy, typically containing ≥99.99% copper, with extremely low oxygen content. It offers superior electrical conductivity (often at or above 101% IACS) and excellent thermal conductivity. Being oxygen-free, it is ideal for applications demanding minimal oxide inclusions, such as semiconductor components, high-frequency cables, and transformer windings. Its high purity and ductility also make it well-suited for vacuum devices and electron tube systems.

• C10200 (Oxygen-Free Copper)
  

  Similar to C10100, C10200 is also an oxygen-free copper, though with slightly lower purity requirements—usually ≥99.95% copper. It retains excellent electrical (close to 101% IACS) and thermal conductivity. Common applications include welding rods, precision electronic components, vacuum seals, and other high-performance electrical systems where low oxide content is beneficial.

• C11000 (Electrolytic Tough Pitch Copper)
  

  C11000, commonly referred to as ETP copper, is known for its high purity (≥99.90% copper) and outstanding electrical conductivity, typically around 100% IACS. It remains the most widely used copper in electrical applications, such as power cables, switchgear components, and connectors, offering a cost-effective balance of performance and availability.

• C12200 (Phosphorus-Deoxidized Copper)
  

  Deoxidized with phosphorus, C12200 has slightly lower electrical conductivity (approximately 92–94% IACS) compared to C11000. However, its improved weldability, solderability, and corrosion resistance make it a popular choice for plumbing, heat exchangers, and other applications requiring excellent formability and thermal performance.

Other Common Copper Alloys

• Tellurium Coppers (C14420 & C14500)
  

  Tellurium coppers are prized for their excellent machinability and good electrical conductivity. By adding small amounts of tellurium (Te) and sometimes tin (Sn), these alloys retain most of the pure copper’s conductivity while improving free-cutting characteristics (making them easier to stamp, machine, or form). They are frequently used in electrical connectors, automotive parts, and other applications requiring both conductivity and relatively easy fabrication. Because of the tellurium addition, they can achieve up to 90–95% of the conductivity of pure copper, yet they cut or stamp with less tool wear.

• Copper Zirconium (C15500)
  

  Copper zirconium (CuZr) alloys incorporate a small percentage of zirconium (Zr) to increase strength and high-temperature performance without severely compromising electrical and thermal conductivity. They are popular for parts exposed to elevated temperatures—such as welding electrodes and automotive connectors—because they resist softening and maintain mechanical integrity. For metal stamping, C15500’s strength-to-conductivity balance allows for durable, heat-resistant components with efficient electrical properties.

• Beryllium Coppers (C17200 & C17410)
  

  Beryllium copper alloys are known for combining high strength, hardness, and conductivity. C17200 (Alloy 25) and C17410 exhibit excellent spring qualities, making them ideal for high-performance electronic connectors, precision instruments, and automotive components under repetitive or high-stress conditions. Beryllium copper can be precipitation-hardened to achieve tensile strengths over 1,400 MPa (200 ksi), which is unusually high for a copper alloy. Despite their superior mechanical properties, they still offer decent electrical conductivity, which is critical in many connector applications.

• Chromium Copper & Copper-Chromium-Zirconium (C18080 & C18150)
  

  Alloys like C18080 (CuCr) and C18150 (CuCrZr) feature chromium (and sometimes zirconium) additions. The chromium significantly boosts hardness and strength, while retaining good electrical and thermal conductivity. C18150 (Copper-Chromium-Zirconium) is often used in resistance welding tips, high-strength conductors, and heat exchangers because it resists wear and retains conductivity under load. In stamping, these alloys provide a balance of formability and mechanical strength, suitable for high-load parts requiring reliable electrical pathways.

• Copper-Iron Alloy (C19400)
  

  Often referred to as CuFe2P, this alloy contains iron (Fe) for enhanced strength and wear resistance, while still maintaining good electrical conductivity. It finds frequent use in connectors, automotive components, and other applications demanding a combination of durability, moderate conductivity, and corrosion resistance. In stamping, its strength allows for the production of thinner and lighter parts that can still withstand mechanical stresses—an increasingly important trait for modern, high-efficiency designs.

• Brasses (C21000, C22000, C23000, C24000, C26000, C26800, C27000, C28000)
  

  Under the broad “brass” umbrella, these alloys combine copper (Cu) with varying levels of zinc (Zn) and sometimes small amounts of tin (Sn) or other elements:

• • Gilding Metal (C21000) has a high copper content (~95%) for a rich color, used in decorative applications and coinage.
  • Commercial Bronze (C22000) and Red Brass (C23000) are stronger than pure copper but still fairly ductile, and popular for springs, connectors, and mechanical parts.
  • Low Brass (C24000) and Cartridge Brass (C26000) are known for excellent formability, making them staples of deep-drawn and high-speed stamping processes (e.g., ammunition casings).
  • Yellow Brass (C26800 & C27000) is widely used for furniture hardware and architectural components for its pleasing yellow hue, corrosion resistance, and good workability.
  • Muntz Metal (C28000) has a higher zinc content (~40%) and is valued in marine fittings and heavy industrial applications.
  • Overall, brasses offer an attractive balance of ductility, corrosion resistance, and cost-effectiveness, which is why they are so common in stamped parts across multiple industries.

Surface Treatments for Copper in Metal Stamping

Surface treatments for copper in metal stamping can significantly enhance the corrosion resistance, wear resistance, electrical conductivity, and aesthetics of stamped parts. Common methods include electroplating—nickel, tin, silver, or gold—to improve conductivity, durability, or solderability; anodizing, which creates a protective oxide layer; passivation, a chemical process that forms a corrosion-resistant film; polishing and buffing for a smooth, decorative finish; and specialized coatings or paints that add protection or provide electrical insulation. These processes collectively ensure optimal performance and longevity of copper components across various industries.