04 Dec Common myths & misconceptions about copper machining — debunked
Copper continues to be a prominent engineering metal because of its superior electrical and thermal conductivity along with its natural resistance to corrosion and multiple application areas. Its widespread use doesn’t eliminate the challenges copper presents in manufacturing which makes some designers, engineers and procurement teams hesitant. The extensive list of disadvantages stems mainly from false beliefs resulting from outdated or limited knowledge of current machining processes.
In this blog post, we’ll demystify some of the most common myths and misconceptions about copper machining — and expose the truths behind them. From electrical components and heat-transfer products to high-performance mechanical parts, this guide will help you make informed, confident decisions when considering copper.
Myth 1: “Copper is too soft to hold tight tolerances.”
This is the most common myth we have heard in our 80+ years in precision engineering. Copper is softer than many metals (such as stainless steel for example), but softness does not automatically mean poor dimensional control.
The reality
With the proper tooling, cutting parameters and process know-how, copper parts can be made to extremely tight tolerances consistently — even in high production quantities. Advanced CNC technology, carbide and coated tooling, and optimised toolpaths allow machinists to keep parts within dimensional specifications while minimising thermal expansion or deformation.
Myth 2: “Machined copper always burrs badly.”
The ductility of copper means that it is susceptible to burr formation, and this is certainly the case if copper components are machined without optimisation. This has given rise to the perception that it is impossible or uneconomical to machine copper without burrs.
The reality
Copper can be machined with little or no burr formation – in many cases even burr-free – by applying the right combination of tooling geometry, lubrication and process control.
Best practices of deburring and prevention
- Tooling designed specifically for ductile metals reduces burr formation at the source
- Coolant and lubrication help maintain temperature stability and chip evacuation
- Optimised cutting strategies reduce tearing on edges
Targeted deburring solutions such as tumbling, brushing, electrochemical deburring, or hand finishing produce burr-free edges even on complex parts.
The point isn’t to “never touch copper”; it’s to find a machining partner with a proven track record of handling burr formation correctly.
Myth 3: Pure copper stands as the sole material that meets the requirements for electrical applications.
Pure copper stands as the top electrical conductor which explains its dominance in electrical engineering applications. The idea that electrical components must be made exclusively from pure copper represents an oversimplified understanding.
The reality
Many copper alloys offer excellent electrical performance, and greatly increase machinability, durability, and mechanical strength. High-performance copper alloys like Tellurium Copper (CuTe), Beryllium Copper and brass and bronze variants enable designers and engineers to optimise performance, manufacturability, and cost – often outperforming pure copper in specialised applications.
Myth 4: “Copper machining is too expensive compared to other materials.”
The cost of copper is higher than some metals, but the claim that it is “too expensive” ignores long-term performance and the efficiencies of modern machining processes.
The reality
In many cases, copper is more economical over the full lifecycle of a product due to its durability, conductivity, corrosion resistance, and recyclability.
Longer term, copper provides excellent value by decreasing assembly requirements due to more integrated component designs, reduced energy loss in electrical systems, increased heat-transfer efficiency, and high scrap value to offset production costs. When designed properly, these benefits reduce the overall system cost, rather than adding to it.
Myth 5: “Copper can’t be used for complex or high-precision parts.”
When part geometry becomes more complex some engineers are reluctant to specify copper.
The reality
Copper machining today can accommodate shapes, wall thicknesses and tolerances previously considered impossible.
Thanks to multi-axis CNC machining, EDM processes, and highly specialised fixturing, copper is routinely used for:
- Micro-machined components
- Intricate heat-transfer geometries
- High-precision electrical contacts
- Automotive hybrid & EV components
- Medical instruments and RF components
Myth 6: “Copper machining is slow and inefficient.”
The reason this myth persists: Old machining techniques.
The reality
New technologies – such as high-speed CNCs, innovative coolant systems, and optimised tool coatings – mean copper can now be machined quickly and with total reliability. Productivity levels have increased dramatically in the last decade, so copper machining is not only efficient but also highly scalable.
Copper is not a complex or capricious material – it just needs to be treated with the correct knowledge, tooling and mindset. Machining can be executed with precision, reliability and repeatability by experts who know how to work with copper and its alloys, regardless of the size and complexity of the part.
That’s where Luvata Welshpool stands apart
With our proficiency in precision machining and assembly spanning over 80 years and our extensive experience with copper and its alloys, we create top-notch components to exact specifications for industries where reliability must be absolute. The precision expert team at Luvata is known for delivering the highest quality repeatable and tight-tolerance electrical connectors along with high-performance thermal components at unmatched efficiency levels.
Looking for a manufacturing partner that has deep knowledge of copper and knows how to produce its best performance? We can help. We offer guidance on material selection, ultra-precision machining and forming, scalable production from prototype to volume, and a proven track record of success in automotive, medical, aerospace, electronics and more.
Talk to our engineering team today and learn how our copper machining expertise can enhance quality, performance and cost-efficiency in your next project.