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 — also called cold heading or cold forging — shapes copper at room temperature, with no furnace and no chips. Coiled wire is sheared into blanks and driven through a series of carbide dies into a near-net-shape part. The grain flow follows the geometry, so the copper work-hardens as it is formed.
Over half of the world's EV batteries are now LFP, and more than 60% use prismatic cells (IEA Global EV Outlook 2026). Cold forming moves copper into shape instead of cutting it away: almost no material loss and gigafactory-scale output.
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 copper EV parts from the Nedschroef development line: copper bolts and charging connector pins — each at a different stage of readiness, all cold formed from wire in a single continuous process.
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.
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This compilation gives an indication of what is possible in cold formed copper. Not every part shown here is in production yet — but that's exactly the point. We don't just engineer the part, we look at the application it needs to perform in.
As Nedschroef, we work side by side with you: from reviewing your drawing and application to material choice, forming feasibility and first-off-tool samples. Let's explore the possibilities for your copper component together.
Start the conversationWrite your copper or forming challenges on sticky notes. We match each one to the cold formed copper product that makes the most impact.
Cold formed copper pins for NACS, CCS1 and CCS2 — first-off-tool parts made, development continuing on surface quality and precision.
Talk to an engineerPick a topic — we'll walk you through what cold forming is, why copper matters now, and where it fits your application. Right in this window, like a chat.
See how cold formed copper compares with Nedschroef's proven cold formed steel and with CNC machining of copper parts.
| Dimension | CF Steel | CF Copper | CNC 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 formed part in place of multi-step machined or joined parts | Single part, but with high material loss |
| 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 parts 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 | 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, product families in development, and a direct comparison to machining and stamping.
Request the whitepaperQuick-reference leaflet on our cold formed copper capability: key features, product families (copper bolts, charging pins), copper grades (C101/C103/C110/C122), and the co-development approach. Ideal for sharing internally.
Request the leafletOur announcement to the battery supply chain: the LFP and prismatic opportunity, and how cold formed copper parts cut material loss at scale. Written for engineering and procurement contacts.
Follow Nedschroef on LinkedInYes. Cold forming, cold heading and cold forging all describe shaping metal at room temperature by pressing it through dies instead of cutting it. At Nedschroef, copper wire is sheared into blanks and formed through a series of carbide dies into a near-net-shape part, with no furnace and no chips.
Nedschroef is developing two families of cold formed copper parts: M6–M12 copper bolts for battery packs, junction boxes and HV connections (forming trials completed), and charging connector pins for NACS, CCS1 and CCS2 (first-off-tool parts).
Cold forming wins at volume. CNC machining turns most of the copper bar into chips and takes seconds to minutes per part; cold forming moves the copper into shape, wastes almost none and runs at hundreds of parts per minute. Forming needs upfront tooling, amortised at automotive volume, so CNC machining remains the better fit for prototypes, low volumes and complex one-offs.
Often stronger. During cold forming the grain flow follows the shape of the part instead of being cut through, so the copper work-hardens. The finished component is often stronger than the wire it came from, usually without any heat treatment. A machined part keeps the as-supplied properties of the bar, with the grain cut through.
Only slightly. Published handbook data for pure copper shows that even severe cold work lowers electrical conductivity by just a few percent IACS. Nedschroef matches the copper grade and forming sequence to the electrical requirement of each part.
Nedschroef's cold formed copper charging pins are developed for NACS (SAE J3400), CCS1 and CCS2. First-off-tool parts have been made; development continues on surface quality and dimensional precision for high-voltage contact requirements.
The main focus is European gigafactories and the Tier-1 suppliers that serve them: EV battery terminals, interconnects and pack bolts, and EV charging pins. The same forming advantage applies to stationary energy storage, solar inverter connections, wind turbine fasteners, off-highway EVs and high-conductivity aviation contacts.
Cold forming wastes almost no copper, needs no furnace energy and produces parts that are fully recyclable. CNC machining turns most of the bar stock into chips that have to be collected and recycled. At today's copper prices the material saving also lowers the cost per part.
Nedschroef is a cold forming and fastener manufacturer with more than 130 years of experience in forming steel and aluminium, based in Helmond, the Netherlands. Cold formed copper is its newest capability: the same tooling knowledge, process control and volume mindset, applied to copper.
Use the RFQ form on this page or the contact form, or email info@royalnedschroef.com. Share the application, dimensions and annual volume, and a Nedschroef forming engineer will review feasibility with you. Nedschroef works through co-development: feasibility review, first samples, then series production.
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.
Share your application in the form and a cold forming engineer will contact you to set up a 20-minute conversation.
Request a meetingWhether 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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