Die Stamped Copper Arrays for Automotive Junction Box

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Bus Bar

These bus bar arrays were intended for automotive junction box arrays. Wiegel Tool Works designed a superior tooling technique to reduce tooling costs and guarantee up to 80 forms in one part.

Wiegel Tool Works built modular dies with nitrogen cylinders, which allowed for exact pressure during die stamping, and held up to 80 forms. Using .024" thick copper, C725 and C151, as a base material, we applied electro plated tin according to the client-supplied 3D modeling design, and made sure we met customer standards. The newly designed tooling delivered savings results, and we produced 50,000 to 2,000,000 over the course of a year, shipped to the client in special cell boxes, in accordance with their just-in-time program.

Specifications

Product Description:	Bus Bar used in automotive junction box application
Capabilities Applied/Processes:	Progressive die stamping
Material Thickness:	.024
Material Used:	C725, C151
Material Applied:	Electro plated tin
Industry for Use:	Automotive
Volume:	50,000 to 2,000,000 per year
Delivery Time:	JIT; Once per week
Delivery Location:	USA and Mexico
Standards Met:	Customer prints
Product Name:	Bus Bars
Project Scope:	Build tooling for Automotive Bus Bar application
Design Work:	3D data solid modeling design
Special Inspection:	Sophisticated attribute gages at the press
Special Tooling:	Build modular dies with nitrogen cylinders for exact pressure and to hold up to 80 forms.
Special Packaging:	Cell box