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Electronics & Electrical — Shaped Wire & Profile Wire
Copper and aluminium sections carry current where round wire will not fit.
Connectors, busbars and terminals are usually designed around a rectangular or square interface, not a round one. A drawn square or flat profile gives a defined contact face, a predictable assembly height and a repeatable insertion force — three things a round wire cannot guarantee.
We draw copper, brass and aluminium profiles with controlled conductivity and a clean, oxide-free surface for plating or direct contact. Sections can be drawn to your connector drawing, including keying features and radiused corners.
Typical parts we supply wire for
- Busbar and power distribution profiles
- Connector pins and contact blades
- Terminal and crimp profiles
- Transformer and inductor winding sections
- Shielding and grounding strips
Specification at a glance
| Common sections | Square, rectangular, flat, radiused-corner, custom keyed |
|---|---|
| Materials | C1100, C2680 brass, C5191 phosphor bronze, 6061 aluminium |
| Typical size range | 0.4 – 10 mm across the section |
| Tolerance | Down to ±0.015 mm on contact faces |
| Surface | Bright, degreased, plating-ready |
Recommended cross-sections
What helps us quote quickly
- Send the connector drawing with the contact face marked — that face sets the tolerance we hold.
- Specify the temper you need; soft copper forms easily but a harder temper holds spring contact.
- For press-fit parts, corner radius and burr height matter more than overall size.
Other industries we serve
Ready to start your project?
Send us your drawing or sample — we reply within 24 hours on working days.