Manufacturing Capabilities
20 years of precision copper connector manufacturing. ISO 9001 certified factory in Wenzhou, China.
Factory Overview
Yulian operates a dedicated copper flexible connector manufacturing facility in Yueqing, Wenzhou — the heart of China's electrical manufacturing hub. Our factory combines 20 years of process expertise with modern automated production equipment to deliver consistent quality at competitive lead times.
- Floor area: 5,000+ m² production space
- Workforce: 50+ skilled technicians and engineers
- Annual capacity: 2 million+ copper flexible connectors
- Export ratio: 60%+ to Europe, Americas, Asia-Pacific
- Material inventory: 50+ tons of copper strip/braid in stock
- Tooling library: 500+ sets of custom molds, dies, and jigs
- Minimum order: 100 pcs per design (sample orders welcome)
- Typical lead time: 7–15 working days for standard orders
Production Workshops
Our manufacturing process is organized into five specialized workshops, each equipped with purpose-built machinery and dedicated quality checkpoints:
1. Braiding Workshop
- High-speed copper wire braiding machines (24/36/48 carriers)
- Round braid: 0.05–0.30 mm individual wire
- Flat braid: 6–150 mm width
- Automatic tension control for uniform braid density
- In-line spark testing for insulation integrity
2. Stamping & Cutting
- CNC turret punch presses (30+ ton)
- Progressive die stamping for high-volume terminals
- Copper strip slitting: 0.05–1.0 mm thickness
- Laser cutting for prototype and complex shapes
- Automatic length cutting ±0.5 mm tolerance
3. Welding Workshop
- Diffusion welding press (vacuum + inert gas)
- Resistance brazing machines for terminal ends
- Ultrasonic welding for thin foil stacks
- Explosion welding for bi-metal (Cu-Al) joints
- 100% pull-test on welded joints (≥80% base strength)
4. Surface Treatment
- Automated electroplating lines: tin / nickel / silver
- Electroless nickel plating for complex geometries
- XRF thickness measurement (±0.1 μm accuracy)
- Salt spray test chamber (ASTM B117)
- Anti-tarnish passivation for bare copper
5. Assembly & Finishing
- Insulation sleeving: PVC, silicone, heat-shrink, Nomex
- Custom bending: 45°/90°/Z/U profiles
- Laser marking: part numbers, ratings, QR codes
- Final dimensional inspection (CMM)
- Custom packaging: individual bagging, labeling, kitting
Quality Management System
Quality is integrated into every step of our manufacturing process — not just final inspection. Our ISO 9001:2015 certified QMS covers incoming material inspection, in-process quality gates, and final testing.
| Quality Gate | Inspection Method | Frequency |
|---|---|---|
| Incoming copper material | Spectrometer analysis (Cu purity ≥ 99.90%), conductivity test | Every batch / heat lot |
| Braid density & dimension | Optical comparator, micrometer, weight-per-meter | Every production run, first piece |
| Weld integrity | Pull-force test to destruction, visual inspection | 1 per 100 pcs per run |
| Plating thickness | XRF (X-ray fluorescence) analyzer | Every plating batch |
| Contact resistance | Micro-ohmmeter (4-wire Kelvin method) | 100% of production |
| Dimensional inspection | CMM (Coordinate Measuring Machine) | First article + 1 per 100 pcs |
| Salt spray corrosion | ASTM B117 chamber (48–96 hours) | Per plating process, monthly |
| Final visual inspection | Trained QC inspector, AQL sampling plan | 100% before packaging |
Certifications & Compliance
Yulian holds established industry certifications covering quality management, environmental management, and product safety compliance. Detailed certificates are available on our dedicated Certifications page.
- ISO 9001:2015 — Quality Management System (certified)
- RoHS Compliant — All standard products (EU Directive 2011/65/EU)
- REACH Compliant — SVHC-free materials declaration available
- CE Marking — Applicable products declared per EU Low Voltage Directive
- IEC 61439 — Low-voltage switchgear and controlgear assemblies
- UL recognition — Available for specific product families on request
OEM & Custom Manufacturing Capability
As a factory-direct manufacturer, we welcome OEM and custom projects of any complexity. Our engineering team works directly with your drawings, 3D models, or physical samples to develop production-ready designs — no middlemen, no markup.
- Design support: Our engineers can optimize your connector design for manufacturability and cost
- Prototyping: 3–5 working day turnaround for first-article samples
- Private labeling: Custom packaging, laser marking, and labeling per your brand requirements
- Consignment inventory: Available for customers with scheduled delivery programs
- NDA protection: Standard NDA available for proprietary designs