Which copper alloys are best for high-conductivity three-dimensional printed parts?
Which Copper Alloys Are Best for High-Conductivity 3D Printed Parts?
Copper C101 (OFE Copper)
Copper C101, also known as Oxygen-Free Electronic (OFE) copper, is the premium choice for high-conductivity applications. With a purity level of 99.99% and thermal conductivity reaching up to 391 W/m·K, it achieves up to 101% IACS (International Annealed Copper Standard) in wrought form. In 3D printing, when processed via EBM or DMLS, and densified using Hot Isostatic Pressing (HIP), it retains electrical conductivity levels over 95% IACS, making it ideal for electrical contacts, EMI shielding, and RF waveguides.
Copper C110 (ETP Copper)
Copper C110, or Electrolytic Tough Pitch copper, offers excellent workability and good conductivity, typically rated at 100% IACS in traditional form. In 3D printing, C110 shows slightly lower conductivity due to residual porosity but remains a cost-effective and widely used material for applications requiring strong electrical and thermal performance, such as battery busbars and electrical connectors.
GRCop-42
GRCop-42 is a high-performance alloy developed by NASA, composed of copper, 4% chromium, and 2% niobium. Although its electrical conductivity (~80% IACS) is lower than pure copper grades, it offers superior high-temperature strength and thermal conductivity above 300 W/m·K. It is ideal for heat exchangers and combustion chamber liners in aerospace propulsion systems produced through laser metal deposition (LMD) and DMLS.
CuCr1Zr
CuCr1Zr offers a balance between strength and conductivity. With electrical conductivity of 75–85% IACS and good wear resistance, it is commonly used in applications such as electrodes and cooling components for welding equipment. It performs well in powder bed fusion environments, where stable thermal cycling is required.
Best Services from Neway for High-Conductivity Copper Alloys
Copper Alloy 3D Printing: Access optimized 3D printing for Pure Copper, C101, and GRCop-42 for high-performance thermal and electrical solutions.
Conductivity-Enhancing Post-Processing: Improve density and grain structure via HIP, heat treatment, and surface methods like electropolishing.
Industry-Specific Engineering Support: Tailored design and material recommendations for industries such as aerospace and aviation, energy and power, and electronics.
