Brass End Caps
High Conductivity Brass Material: Engineered using H62/H65/H68 brass alloys, delivering optimized electrical conductivity and structural strength for high-current protection systems.
Precision Stamping & Deep Drawing: Controlled by progressive dies with stamping tolerances within ±0.01mm, ensuring uniform wall thickness across every inner end cap and shell.
Low Contact Resistance Plating: Multi-layer Ni, Sn, or Ag surface finishes protect against oxidation, lowering thermal buildup and contact resistance over long duty cycles.
Integrated Assembly Solderability: Optimized material composition and clean surface treatment allow continuous, void-free soldering to fuse bodies and conductive terminals.
Rapid OEM/ODM Customization: In-house tooling development enables rapid prototyping from STEP/DWG files within 7 to 10 days for high-voltage protection projects.
- Fast Delievery
- Quality Assurance
- 24/7 Customer Service
Product Introduction
In high-voltage EV protection systems and industrial circuit protection modules, thermal stability and consistent current conduction depend heavily on precise end-cap interfaces. A high-quality Brass End Caps must maintain structural integrity under extreme temperature cycles without increasing overall internal resistance. As a source manufacturer specializing in high-precision metal stamping, we supply custom brass end cap components, brass tube cap options, and inner end cap structures engineered specifically for reliable electrical connection and mechanical housing.
Technical Specifications & Material Standards
| Base Material Grade | H62 / H65 / H68 Brass |
| Electrical Conductivity | ≥ 25% IACS (Standard Brass) / Customized Copper-Brass Alloys |
| Plating Options | Flash/Bright Tin (Sn: 3–8 μm), Nickel (Ni: 2–5 μm), Silver (Ag: 2–5 μm) |
| Contact Resistance | ≤ 0.8 mΩ |
| Tensile Strength | 350 – 480 MPa |
Application Scenarios & Industry Integration
New Energy Vehicles (EV/HEV)
Applied in BMS, OBC, and MCU high-voltage fuses to handle rapid current surges and electrical fluctuations for Brass Terminal Cap.
Smart Grid & Power Distribution
Deployed in substations, distribution boxes, and grid equipment for fast fault response and arc suppression for Brass Pipe End Cap.
Aerospace & Defense Avionics
Built for satellite power and aircraft avionics fuses to withstand extreme temperatures and radiation Brass Tube End Cap.
High-End Electronics & Medical
Protects enterprise servers, test instruments, and medical devices under continuous high-load operations for Brass End Caps.
Frequently Asked Questions
Q: How does your silver/tin electroplating process ensure low contact resistance and prevent oxidation on a brass fuse cap?
A: We apply an under-plate nickel barrier (2–3 μm) followed by precision silver or tin plating. This dual-layer process prevents zinc migration from the brass substrate, keeping contact resistance below 0.8 mΩ and preventing oxidation under high-temperature conditions.
Q: Can you manufacture a custom Brass End Caps with deep drawing features and tight wall thickness tolerances?
A: Yes. Using multi-station deep drawing presses and WAIDA PG-processed tooling, we maintain uniform wall thickness within ±0.01mm on deep-drawn brass inner cap parts, eliminating stress concentrations during high-speed automated assembly.
Q: What quality control documentation do you provide for custom OEM brass cap orders under IATF 16949?
A: Every production lot includes a Material Mill Certificate, XRF Plating Thickness Report, CMM Dimensional Inspection Data, Salt Spray Test Results, and full PPAP Level 3 documentation upon request for complete supply chain traceability.
Contact Us
Send us your 2D/3D CAD drawings (STEP/DWG) or electrical specifications for a rapid DFM review and factory-direct quote within 24 hours.
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