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Motor Parts
Copper Parts Manufacturing at BMS Click here to view our manufacturing product lines
We are Contract-Manufacturers of specialised in Copper Component Producing Technology. One wing of our unit is solely devoted to Copper.

This wing processes Custom-Built Copper Parts, Components & Sub-Assemblies for OEM Electrical Industry with Specialized Focus on Automotive, Marine, Power Transmission (HT/LT) & Consumer Electrical Industries.

We specialize in Design/Development & Production as per Clients' Specifications.

Servicing reputed OEM brand Owner Electrical clientele in Europe, USA, New Zealand & Australia, we have mastered the Art of various Processing Technologies to produce Copper Components in all forms of purity right up to the electrolytic type which is the purest form of copper (used as electrical conduction)

Our Professional Systems & Procedures of Design, Development, & Manufacturing to ensure Cost Effective Quality Copper Products are sequentially mentioned below.








Our Engineering Capabilities
Development & Production of High Precision Copper components as per Custom Design, with Intricate Shapes & Profiles having close tolerances & Accuracy.
Expertise in Manufacturing Engineering with subjective Knowledge of Standards, Materials, Manufacturing Processes & Tool Making, to produce Copper components for Electrical, High/Low Tension Power Transmission & Electronics
Expertise in 3D & 2D Software enable us to achieve successful results.
Controlling Wastage in Raw material by Dexterously Designed Tooling & Process Controls enable us to get optimized material utilization.
Providing Total Solution inclusive of Post-manufacturing Processes like Surface Finishing, Coating / Plating, Heat Treatment & Other allied processes like Soldering, Silver soldering, Brazing, etc.
Thorough Understanding of Client’s Design specifications & functional requirements of the end product for Electrical & Electronic Applications
Reverse Engineering Services & Assistance in carrying out Design Activities / Design Up-gradation & adopting suitable manufacturing processes to achieve Clients desired cost effective solutions.
Expertise in fault finding and research capability, for applying corrective action.



Our Products
Copper Components for Rotary Switches, Control Panels & Heavy Duty Current Carrying Applications like Power Transformers, Switch gears etc. like :
CONTACTS FUSE HOLDERS
BUS BARS FASTENERS / WASHERS
TERMINALS CLIPS
CONNECTORS SPRINGS & WIRE FORMS
RELAYS COPPER PIPES & FITTINGS
COMMUTATORS CUSTOM MADE COPPER
COMPONENTS & ASSEMBLIES
AS PER CLIENTS SPECIFICATIONS
ROTOR BAR



Industries served by us
  ELECTRICAL SWITCH GEARS
& CONTACTORS

  ELECTRICAL HIGH/LOW TENSION
POWER TRANSMISSION

  AUTOMOTIVE ELECTRICALS
  MARINE ELECTRICALS

  ELECTRONICS

  HARDWARE & FASTENERS

  REFRIGERATION &
TEMPRATURE CONTROL



types of copper materials used
We use Copper, Copper Alloys & other Non-ferrous materials in various forms such as Sheets, Strips / Coils, Rods / Flats & Sections, Forging & Castings etc as follows

99.9 % Purity Electrolytic Copper
Commercial Grade Copper
Specialty Copper Alloys like Beryllium Copper ,Chromium Copper, Zirconium Copper , Tellurium Copper etc per international standards
Traditional Copper Alloys like Brass, Bronze, Gun Metal etc
Other Metallurgical variants as per international Standards





Our Edge in Processing Technologies / Manufacturing
We look at Copper from the microscopic levels like grain homogeneity & orientation, while manufacturing of components having extreme close tolerances and finishes:
Our Manufacturing/PROCESSING Activities Include ....
Forging Stamping
FORGINGS in closed and open dies : Achieving Odd Shapes & Profiles of Copper Components is our speciality

UPSET FORGINGS : Achieving high ratio of flared Heads coupled with high eccentricity and combination of multiple profiles on the heads of Copper Components is our specialty
Sheet Metal FORMING & PRESSED COMPONENTS
Precision Cutting & Forming Complex Profiles of Copper components with focus on electrical applications like Contact Snap Locking, Smooth Surfaced Contact Domes at Controlled Distances etc is our specialty
Copper PRECISION MACHINED PARTS
Ability to Machine Complex Profiles, while Maintaining Extremely Close Tolerances & very High Finish.
Specialty Welding & Jointing Brazing / SOLDERING
We are experts at Silver Soldering, / Brazing / Soldering etc. to ensure good Capillary Action & without any Porosity to optimize Electric conductivity
Copper Fabricated Components
Copper Critical Assemblies
Copper SPRING & WIRE FORMS

OUR Association of Advanced Manufacturing Units
We are vertically integrated with a team of various Associated ISO 9000 accredited Manufacturing Units, each specializing in a specific field of production Activity to ensure optimum quality with on time deliveries:
manufacturing FACILITIES & QUALITY assurance INCLUDES
Precision Machined Shopequipped with CNC Turning and
Milling centers, SPMs, & Automats like Traubs, Conventional Machines like Lathe & Drilling, Grinding, Milling, Roll Threading Machines, Ultrasonic Cleaning & Vibrator Deburring. Tool Room & Auxiliary equipment facilities for Attachments & Fixtures.
sheet metal press shopequipped with Shearing Machines,
Power presses, Hydraulic Power Presses, Press Brakes, CNC Turret Press, Vibrator Deburing Machines & Fully Equipped Tool room with sophisticated Measuring Instruments.
forge shopequipped with Induction Heating Facilities for small
Upset forgings, Up-setters for head forming operations, Furnaces with Automatic Temperature Controllers, Power Press (Pneumatic Hydraulic & Mechanical) ,Friction Drop Hammers, Fully Equipped Die Shop & Tool Room.
soldering setup equipped with advanced Equipments
Specialty Heat Treatments Facilities We have access
to facilites for Specialized Heat Treatments like Nitrogen Annealing, Precipitate Hardening, Homogenizing etc
Specialty Surface treatments & Plating facilities  We
have access to facilites for surface treatments & Plating like Chrome, Gold, Silver, Tin, Cadmium, Chrome, Nickel / Electroless Nickel, acid washing etc. These units have Automatic Electronic controlled equipments to regulate plating thickness.
quality infrastructureincludes Shophisticated Measuring
Equipments like Surface table, digital height gauge, Digital Precision Micrometers, Profile Projectors, Surface finish measuring gauge, sign bars, bench centers and all other standard Inspection Equipments.
consulting Testing & Metallurgical  Laboratories  & Agencies
consulting Testing & Metallurgical  Laboratories  & Agencies having international accredition & equipped with advanced
facilities like Computerised Spectrometer for chemical analysis, 3D Coordinate Measuring Machines (CMM), Tensile and compressive load test machines, NDT set up, etc.
QUALITY PROCEDURES (STAGEWISE)
at raw material stage
Inspection and identification of the material at Electrolytic forming stage of Ingot to ensure that the defective portions of the Ingots are discarded correctly.
Chemical analysis for Purity, ensuring the composition as per required grade.
Ultrasonic tests of Extrusion Bars & Rods
Checks for Work Hardening of Rolled Sheet
at manufacturing stage
1st piece Inspection.
Patrol inspection (SPC for critical close controlled dimensions),
Final Inspection by SQC Method
Checks for Work Hardening of Rolled Sheet
for FORGINGs & stampings
Inspection for folds and cracks
for sheet metal press parts
Inspection of grain directions of formed profiles. (1st piece for corrective action).
BRAZING/SOLDERING JOINTS
Testing of Ultimate tensile/shear strengths to ensure Specifications.
Microscopic Inspection of sectioned pieces for Electric Conductive and Current Flow Tests for Joints
Small/Large
Precision Dome Forms
Speciality Soldering & Buss Bars
Copper Pipes & Fittings
Brass Bronze & Traditional Copper Alloys
Copper Rods, Flats & Sections
Copper Sheets, Strips & Coils
Forge Shop
Profile Projector
CNC Machines
Precision Turning
Precision Drilling / Tapping
Speciality Soldering & Joining
Precision
Quality Procedures
Quality Procedures
Quality Procedures


Intricate copper Components developed by us
We have developed various intricate Copper items requiring sophisticated machines for processing and have operators with good skills. Some of the products are listed below:

Precision Machined Components developed by us

Precision Milled Collets Precision Milled Collets
Slender 100mm Deep Milled slits compared to Ø 35 mm and heavy thickness of the Wall
Fine slit Milling with many inline slits, alternate slits being in opposite directions.

Precision Machined Contractor Precision Milled Collets
Involves Precision Turning and Eccentric Milling using Carbide Tipped Milling Cutters.
Required constant monitoring with special purpose dedicated gauges

Co-ordinate drilling/boring Co-ordinate drilling/boring
Co-ordinate drilling required due to precision positioning of holes
Milling of the Slit done at the end of all operations, to eliminate dimensional variations due to springing open of the slit.
Deburring the Cross hole that is intersecting the Milled Slit required high skills.


Sheet Metal developed by us

ISOLATING CONTACTS ISOLATING CONTACTS
8 Arms Contact required development of dedicated Collapsible inserts form holder for processing
The intricate shape calls for Skills & care to eject the component from the tool.
The Operation is done on a Hydraulic press, with variable controlled speeds, that are required at various stages of the forming cycle.
Material saving is achieved by designing the Blanking Tool to match intricate strip lay-out consisting interlocked fingers.

grip CONTACT grip CONTACT
Forming the 3 mm thick sheet with 1.5 mm slit & Narrow U Bend of critical Inner radius without springing back, called for a tool of unique design
Slitting was done after complete forming to avoid distortion.
Deburring of the slits was done by Ultra-sonic cleaning, to avoid formation of inside burr.

Switching Contacts with Smooth Dome Profiles Switching Contacts with Smooth Dome Profiles
Forming accurately Projected Domes of exactly equal heights at the extreme edges, without the plate bending, is a specialty in tool designing.
Precision Shearing free of burrs was also a specialty in tool design

Specialty Copper Cable Connectors Specialty Copper Cable Connectors
2,5 mm Thick Main Connector required Fine Blanking Tools & specialized Process.
Critical Bending of the Notched End required extra care & presicion
Pressure spin riveting for Joining the thin Copper Lug to the thick Thick Main Connector to ensure solid joint without any air gap.


PRECISION FORGING DEVELOPED BY US

Heavy-duty Copper contactors for Battery Switches Heavy-duty Copper contactors for Battery Switches
Forged Contact, with large eccentric upset wherein 7mm Ø bar is Spread to 452 sq mm at 25mm eccentricity.
By our know-how we innovated a unique process to achieve minimum waste, thus maximum cost saving. Forming this profile by conventional Head Forging would result in huge copper wastage due to large one sided Flanged Head.

Flat Angular Forged Terminals. Flat Angular Forged Terminals.
Flat bar forged to form flat tang of 8mm thickness with Forged bend to required angle.
Complex milling fixtures were made to ensure high precision squareness and flatness at the desired angle with respect to the rod

Forged Heavy Terminals  Bolt  weighing 1 kg Forged Heavy Terminals  Bolt  weighing 1 kg
1.25” bar upsetted to 2.5” Ø x 3/8 thick flattened top.
Then precision Machined to achieve various Diameter on the Bolt Stem.


SPECIALITY SOLDERING JOBS DONE BY US

3mm THIN COPPER BUSS BARS 3mm THIN COPPER BUSS BARS
Silver soldering of 3/8” UNC studs into 3mm thick copper Bus bars.
Capillary action of the silver solder through the entire thread length maintained to achieve Sturdy Joint while ensuring Perfect Conductivity.

6mm to 10mm Thick Buss Bars Copper Bus with 3/8 Studs 6mm to 10mm Thick Buss Bars Copper Bus with 3/8 Studs
Silver soldering of 3/8” UNC studs into Tapped Holes of the 6 and 10mm thick copper Bus bars.
Capillary action of the silver solder through the entire thread lengths maintained to achieve Sturdy Joint while ensuring Perfect Conductivity (To Carry 400 & 800 amps capacity)


Heavy Assemblies DEVELOPED BY US

Heavy Duty Terminal Assemblies Heavy Duty Terminal Assemblies
Large & Thick Copper Flats are precision machined to flatness, parallelism and thickness within 0.02mm T.I.R
Silver brazing the tang into a rod involving complex fixturing to ensure that:
  Alignment is within 0.05mm T.I.R.
  The brazing through capillary action covers the whole joint area giving strength and excellent conductivity. (Being conductors for very heavy current flows)
Co-ordinate drilling after brazing to ensure accuracies