In modern power cable, transformer, switchgear and electric vehicle manufacturing, the demand for high-conductivity, soft-temper copper conductors with excellent surface quality and dimensional precision continues to rise. Traditional multi-step drawing, rolling or hydraulic extrusion processes often involve intermediate annealing, edge trimming, pickling and significant material loss. The Copper Material Continuous Extrusion Machine (Conform continuous rotary extrusion line) provides a proven single-wheel lateral extrusion solution that converts oxygen-free copper (OF Cu) rods directly into soft, high-conductivity round wires, flat wires, busbars and complex profiles in one continuous, high-speed process.
The continuous extrusion machine for copper (Conform process) converts oxygen-free copper (OFC) or low-oxygen copper rod feedstock directly into finished busbars, flat wires, round rods, strips, and custom profiles in a single continuous operation. Friction between the rotating grooved extrusion wheel and the copper rod generates the heat required for plastic deformation (typically 400–700 °C), eliminating the need for external billet preheating or intermediate annealing in most applications. First-pass material utilization reaches 95–99 %, product length is theoretically unlimited, and the resulting microstructure is fully recrystallized with refined grain size (often <25 μm) and high electrical conductivity.
How Continuous Extrusion for Copper Works
The process is a solid-state, friction-driven forming technology. Oxygen-free copper rod (typically Φ12.5–30 mm depending on model) is paid off from a coil, straightened and continuously fed into the circumferential groove of a rotating extrusion wheel. Friction between the rod, the wheel groove and the stationary shoe generates the necessary heat (typically 400–500 °C) and driving force. The material becomes highly plastic, is upset against an abutment, and is then forced radially through a precision die to form the final profile.
Key Technical Advantages
- Material utilization 95–99 % with near-zero process scrap.
- Energy consumption significantly lower than traditional billet extrusion + annealing routes (friction supplies the majority of heat).
- Unlimited continuous length — ideal for long busbars, magnet wire, and joint-free conductors.
- Superior metallurgical quality: dense microstructure, refined grains, excellent surface finish, and conductivity typically ≥100 % IACS when using quality OFC feedstock.
- High productivity: 400–4 000 kg/h depending on machine size and section.
- Simplified process flow — no heating furnace, no intermediate annealing, no acid pickling or edge trimming required for most products.
- Flexible die change allows rapid switch between flat wire, busbar, rod, strip, and custom profiles.
Typical Applications in Cable & Electrical Industries
- Copper busbars and profiles for switchgear, transformers, data-center power distribution, and EV battery systems.
- Flat magnet wire and commutator segments for motors and generators.
- High-conductivity rods and shaped conductors for power cables and railway contact wire.
- Continuous-length strip and rectangular conductors for CTC (continuously transposed conductors) and renewable-energy installations.
- Custom profiles for heat sinks, terminals, and precision electrical components.
The Conform Continuous Rotary Extrusion Process for Copper
The RLB Copper Continuous Extrusion Machine employs advanced continuous rotary extrusion (CRE / Conform) technology. Oxygen-free copper rod feedstock is fed into a precision-grooved rotating extrusion wheel. Intense friction and controlled pressure generate localized heat, bringing the material into a plastic state where dynamic recrystallization occurs. The material then flows into the die chamber and exits as finished high-conductivity product of unlimited length in a single, continuous operation — without the need for preheating or post-extrusion annealing in most applications.
Key advantages for copper processing:
- Preserves and enhances the inherent high conductivity of oxygen-free copper
- Produces soft temper material ideal for direct bobbin take-up or further forming
- Excellent bendability and formability for complex busbar shapes used in EV and switchgear
- Significantly higher material yield and lower energy use than traditional routes
Advanced Engineering Features & Process Benefits
Lengthened Extrusion Belt & Heat-Treated Wheel
Extended dwell time ensures complete compaction and dynamic recrystallization, delivering dense, homogeneous microstructure with exceptional electrical conductivity and long-term thermal stability. Special heat treatment extends wheel service life under demanding high-pressure and high-temperature conditions.
Single-Wheel Single-Groove Lateral Extrusion
Provides stable high-speed production with precise dimensional control (typical tolerance ±0.05 mm) and outstanding repeatability — critical for tight-tolerance copper busbars and flat wires used in high-current applications.
Soft Extruded Products – Annealing-Free
Copper exits in soft temper, ready for direct bobbin take-up. Optional integrated online cutting saw delivers precise length control for busbar and profile production, eliminating costly and energy-intensive annealing steps.
Compact Intelligent Full-Line Layout
Complete production line includes: horizontal pay-off system, wire straightener, continuous extrusion main machine, cooling & anti-oxidation system, length counter, caterpillar tractor, constant-tension take-up and receiving stands. All modules are linked by automated conveying for seamless 24/7 operation. Centralized PLC + HMI touchscreen with industrial cloud data traceability and remote diagnostics module enables real-time monitoring, parameter adjustment and predictive maintenance.
Energy-Efficient & Eco-Friendly Design
No preheating or annealing required. Integrated hydraulic system with zero oil leakage. Mechanical locking of extrusion tooling guarantees stable process conditions. One or two operators can efficiently manage multiple lines.
Premium Components & Continuous Improvement
Upgraded high-quality gearbox, Siemens/ABB electrical controls, aviation plugs for fast connection, constant-tension take-up and automatic short-rod feeding. Dedicated R&D team and independent laboratory support annual machine improvements and customer-specific material testing.
These features make the RLB Copper Continuous Extrusion Machine the preferred choice for producers seeking higher throughput, lower operating costs, reduced scrap and consistent premium quality in copper busbar, flat wire and profile manufacturing.
Key stages:
- Rod payoff and precision coining into the wheel groove
- Frictional heating and plasticization (no external billet heating required in most copper applications)
- Upsetting and radial extrusion through the die chamber
- Online cooling / anti-oxidation treatment
- Continuous take-up of unlimited-length product
The result is a fully recrystallized, soft-temper copper product with refined grain structure (often <25 μm), dense microstructure, superior surface finish and high electrical conductivity — ready for direct use or minimal further processing.
Technical Specifications
| Model | Extrusion Form | Extrusion Wheel Dia. | Main Motor Power | Rated Speed | Sectional Area | Max. Width | Output (kg/h) | Leak Amount | Raw Material (Oxygen-Free Cu Rod) |
|---|
| RLB285/90 | Single-wheel single-groove | Φ285 mm | 90 kW | 11 r/min | 15–150 mm² | 35 mm | 400 | ≤3 % | Φ12.5 mm |
| RLB350/200 | Single-wheel single-groove | Φ340 mm | 200 kW | 11 r/min | 80–400 mm² | 80 mm | 400–600 | ≤5 % | Φ16 mm |
| RLB400/250 | Single-wheel single-groove | Φ400 mm | 250 kW | 10 r/min | 250–1000 mm² | 160 mm | 400–1300 | ≤5 % | Φ20 mm |
| RLB550/450(355) | Single-wheel single-groove | Φ550 mm | 450 kW | 8 r/min | 400–2400 mm² | 220 mm | 800–2500 | ≤5 % | Φ22 mm |
| RLB600/450 | Single-wheel single-groove | Φ580 mm | 450 kW | 8 r/min | 380–8000 mm² | 315 mm | 800–2500 | ≤5 % | Φ28 mm |
| RLB700/550 | Single-wheel single-groove | Φ700 mm | 600 kW | 6.5 r/min | 600–4000 mm² | 320 mm | 1500–4000 | ≤5 % | Φ28 mm |
Notes: Output values are typical for oxygen-free copper. Actual performance depends on alloy, profile complexity and cooling parameters. Typical dimensional tolerance ±0.05 mm. All models produce soft, high-conductivity products suitable for direct use or minimal downstream processing.
Production Line Layout & Intelligent Control
The overall layout is compact and space-saving while covering the complete process from raw material feeding to finished product winding: pay-off system → wire straightener → continuous extrusion machine → cooling & anti-oxidation device → length counter → traction device → constant-tension take-up → receiving system. Full-process monitoring via PLC/HMI with remote module interface ensures intelligent management, minimal operator intervention and full production traceability — ideal for modern smart factories.
Primary Applications in the Cable & Electrical Industry
- Copper flat wire and rectangular conductors for transformer windings and power cables
- Soft copper busbars for switchgear, distribution panels and high-current connections
- Round copper wire and rods for further drawing or magnet wire production
- Custom profiles and commutator segments for motors and generators
- High-conductivity conductors for EV traction motors, solar inverters, railway contact systems and new-energy applications
Comparison vs Traditional Batch Extrusion
| Parameter | Continuous Extrusion (Conform) | Traditional Billet Extrusion |
|---|
| Material utilization | 95–99 % | 70–85 % (butt & trim losses) |
| Energy requirement | Low (friction heat dominant) | High (billet heating + annealing) |
| Product length | Unlimited | Limited by billet size |
| Grain structure | Refined, fully recrystallized | Variable, often requires anneal |
| Process steps | Single continuous pass | Multiple (cast → heat → extrude → anneal → draw) |
| Typical scrap | Flash only (1–5 %) | Significant butt & edge scrap |
Practical Considerations for Long-Term Operation
Maintain consistent rod diameter tolerance (±0.2 mm recommended), ensure adequate cooling capacity, and schedule regular inspection of the extrusion wheel groove and abutment. Flash must be controlled to avoid re-entry into the groove. Modern lines support remote monitoring of temperature, torque, and production data, supporting predictive maintenance and stable long-term cooperation with end users.
Key Takeaways
Continuous extrusion machines for copper deliver high material yield, lower energy use, unlimited product length, and superior metallurgical quality compared with conventional routes. Models ranging from 300 mm to 630 mm wheel diameter cover sections from small flat wire to large busbars (up to 6 400 mm²) at outputs from several hundred to several thousand kilograms per hour. The technology is established for power distribution, transformer, motor, EV, and cable conductor production.
For detailed technical proposals, capacity matching, die design, or complete line configuration based on your specific section range and annual volume, Inquiry Now.
Copper Continuous Extrusion Machine
High-performance continuous extrusion machine for copper. Converts OFC rod into soft high-conductivity busbars, flat wires & profiles. 95%+ yield, energy-saving, unlimited length. Ideal for cable, transformer & EV.
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Copper Continuous Extrusion Machine1
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RLB Machinery
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