Nedschroef has cold formed metal for over 130 years. Now we're bringing that same precision, repeatability, and near-zero material waste to copper — the material powering every prismatic EV battery cell, charging connector, and high-voltage system in the shift to electrification.
We bring the forming expertise and material knowledge. You bring the application. Together we develop the part — from first design review through to series production.
Cold forming shapes copper at room temperature — no melt, no chip. Coiled wire is sheared into blanks, then progressively formed through carbide dies into near-net-shape parts, with grain flow that follows the geometry and adds strength through work hardening.
Every prismatic LFP battery cell — over 60% of EVs globally — needs a copper anode terminal. Cold forming redistributes copper instead of cutting it away: near-zero waste, gigafactory-scale throughput, and a single formed part replacing welded two-part assemblies.
EV battery terminals and bolts, charging connector pins (NACS/CCS1/CCS2), stationary energy storage, off-highway EVs, renewables, and aviation contacts. Our focus today: European gigafactories and the Tier-1 suppliers who serve them.
Actual parts from our development line: terminal rivets, copper bolts and charging connector pins — each at a different stage of readiness, all formed from wire in a single continuous process.
Single-piece copper anode terminals for prismatic battery cells, replacing welded two-part assemblies. First samples are being produced. We are looking for a co-development partner to validate geometry and performance for their specific cell format.
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M6–M12 copper bolt forms for battery pack assembly, junction boxes, and HV connections. Forming trials completed on multiple standard forms. Closest to our core fastener competency — ready for customer-specific development.
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Cold-formed copper pins for NACS, CCS1 and CCS2 charging formats. First-off-tool parts produced; development continues on surface quality and dimensional precision for HV contact requirements.
Discuss this partWrite your copper or forming challenges on sticky notes. We match each one to the cold formed copper product that makes the most impact.
Single-piece copper rivet replaces welded two-part assemblies. Consistent DCIR at gigafactory scale.
Talk to an engineerFive short cards. One minute. Everything an engineer or buyer needs to decide whether cold formed copper deserves a closer look.
Coiled copper wire is fed into a multi-station machine, sheared to length, then pushed through progressive carbide dies at room temperature. No melt, no chips — just precise, high-speed forming. Every stroke ejects a finished part while a new blank enters the first die. Production rates: hundreds of parts per minute.
See how cold formed copper stacks up against Nedschroef's proven cold formed steel and traditional machining.
| Dimension | CF Steel | CF Copper | Machining |
|---|---|---|---|
| Material utilization | High — near-net-shape, minimal scrap | High — copper redistributed, not cut away (decisive at Cu prices) | Low — most bar stock removed as chips |
| Production rate | Hundreds of parts per minute | Hundreds of parts per minute — gigafactory-scale | Seconds to minutes per part |
| Part strength | Work-hardened, grain flow follows geometry | Work-hardened — often stronger than the raw wire, no heat treatment needed | As-supplied material properties, grain cut |
| Assembly complexity | Single formed part | One part replaces welded two-part terminal assemblies — no weld, no joint variability | Single part, but often paired with welding for terminals |
| Contact resistance (DCIR) | N/A | Consistent across millions of parts — no weld interface | Consistent per part; welded assemblies introduce variability |
| Tooling investment | Upfront, amortized at automotive volume | Upfront — tooling for automotive rivets also serves stationary storage | Low upfront, higher per-part cost |
| Sustainability | Low waste, no furnace energy | Near-zero waste, no furnace energy, fully recyclable | Chip waste; recycling loop for copper swarf |
| Best-fit applications | Fasteners, structural automotive components | Terminal rivets, copper bolts M6–M12, NACS/CCS charging pins, HV connectors | Prototypes, low volume, complex one-offs |
A working reference for engineers and buyers: copper grades and properties, what changes when you cold-form copper instead of steel, and why DCIR consistency has become the KPI that decides gigafactory sourcing.
The full technical and commercial case: the prismatic LFP opportunity, European gigafactory demand, why cold forming beats welding for terminal rivets, three product families in development, and a direct comparison to machining and stamping.
Quick-reference leaflet on our cold formed copper capability: key features, product families (terminal rivets, copper bolts, charging pins), copper grades (C101/C103/C110/C122), and the co-development approach. Ideal for sharing internally.
Our announcement: 55%+ LFP, 60%+ prismatic, 6 European gigafactories — and how a single cold-formed terminal rivet replaces a welded two-part assembly. Written for engineering and procurement contacts across the battery supply chain.
Tell us what you're working on. Whether it's a whitepaper, a sample, or a technical review — we'll route you to the right engineer.
Talk directly with one of our cold forming engineers about your application, tolerances, or supply questions. No pre-qualification calls — you get an engineer.
Whether you're scoping a project or comparing suppliers, a 20-minute call with an engineer is the fastest way to know if cold formed copper fits.
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