Custom Brass Component Manufacturing—Applications, Processes & Guidelines

Brass has been manufactured nearly as long as copper. However, this golden-colored metal has gained appreciation as a technical alloy only in the last millennium. Brasses are alloys of copper, with zinc as the main alloying element. The proportion of the two metals in the alloy varies depending on industrial requirements. It is commonly used to make valves, doorknobs, casings, bearings, and gears. Its unique properties are also exploited by the aviation sector, which employs precision brass components such as fasteners and enclosures for electrical systems. The properties and color of the alloy are generally determined by the amount of zinc present. It appears reddish-yellow when the zinc content is around 18–20%, and brownish-yellow when it is between 20–30%. Additional elements can be added to enhance machinability, strength, or resistance to specific types of corrosion (Figure 1). Brass has a distinctive combination of qualities that make it easy to shape, emboss, and machine. Hence, it is a prime material for manufacturing a wide range of machined parts and components (Figure 2) used in the electrical, general engineering, medical, aerospace, machine tool, agricultural, and precision engineering industries. Another great advantage of fabricated brass part is that they can be used outdoors or in corrosive environments. They are both waterproof and corrosion resistant.

The characteristics of brass depend largely on the zinc content and the inclusion of other alloying elements. Lower zinc content (18–20%) gives a reddish-yellow color and higher ductility, while higher zinc content (20–30%) produces a brownish-yellow shade with improved strength. Additives like lead, tin, or aluminum further enhance specific properties such as machinability, hardness, or corrosion resistance. Thanks to this adaptability, brass is used to manufacture a wide range of products: • Valves, couplings, and fittings for plumbing and HVAC systems. • Electrical connectors, terminals, and casings due to its excellent electrical conductivity. • Fasteners, sleeves, and enclosures in aerospace and defense applications. • Decorative hardware, knobs, and handles for consumer and architectural use. Additionally, brass exhibits low friction, non-sparking behavior, and resistance to seawater corrosion, which make it suitable for marine and explosive environments. Its balance of aesthetics and functionality gives engineers and designers freedom to create durable yet visually appealing products.

Brass components are manufactured using several different techniques, as shown in Figure 3. The processing history has a significant impact on their characteristics, not just the composition. Hot rolling of slabs and extrusion or forging of billets are common hot-working methods. Hot-working brass has the primary effect of breaking up the original cast structure, which enhances the mechanical properties and alters the material’s grain direction. Heat treatment does not increase the strength of most commercially available brasses; instead, cold working provides improvements in properties compared to the annealed, soft state. Cold reduction is applied to extruded products such as profiles, bars, rods, wires, and tubes using drawing dies, while cold rolling is used for strips and sheets. The choice of manufacturing process is closely linked to the product’s design and the required production quantity. In general, machining processes are classified as either prismatic, where the workpiece remains stationary, or cylindrical, where the workpiece rotates. Metal is removed from a billet, casting, solid bar, or tubing through machining operations to achieve the desired shape. Brass is exceptionally “short-chipping,” which makes its processing relatively simple. Manufacturers can operate with minimal lubricant and cooling.

Brass Milling:

A block or sheet of brass is placed on a table beneath a spindle that holds a cutting tool. The table pivots and rotates, creating two axes of movement. Components: Pipe fittings, flare fittings, compression fittings, swivel fittings, bulkhead fittings, gunner fittings, musical instruments, and custom brass parts. Industries: Plumbing, medical, electrical, and consumer goods industries. For further information, read https://www.custiv.com/service/cnc-machining-services and https://trimantec.com/blogs/t/machining-processes-overview

Brass Turning:

The process uses a tool to rotate a workpiece while reamers, drills, taps, knurling tools, borers, and grinders operate on it. Discs, shafts, sleeves, and other workpieces with rotating surfaces are commonly machined on lathes. The lathe must be precise to provide a flat, straight finish. The mechanical parts of a brass lathe turning machine are typically made from an alloy of copper and zinc. This manufacturing process is capable of producing high-concentricity, high-finish precision brass components that rely on brass’s strong mechanical properties and wear resistance. Fasteners are exemplary precision-turned brass components with a wide range of applications in machinery and pipeline systems. Components: Brass lamp parts, hydraulic fittings, plumbing fittings, inserts for molding, hose and garden fittings, sanitary fittings, brass sealing screws, and tools used in diamond and jewelry making. Industries: Automotive, electrical and electronics, telecommunications, instrumentation, water pumps, medical, construction, plastics and rubber molding, valve assembly, energy, power transmission, sensors, industrial assembly, hydraulics and pneumatics, and textiles. For further information, read https://www.custiv.com/industry/consumer-durables and https://www.adarbrass.com/brass_turned_parts.html

Brass Stamping:

Precision tools called stamping dies press into sheet brass at extremely high pressure. They cut and form the sheet metal into the desired shape. The shock of the stamping impact is absorbed by the brass hammers, resulting in less damage to the die. Because brass is soft, it ensures minimal friction and prevents sparks from being generated. Hence, stamped brass components are used in electrical and plumbing applications, as well as in heavy weaponry and cartridge casings. Brass’s bright, gold-like appearance and resistance to tarnishing give it strong cosmetic appeal. For jewelry designers, brass stampings are incredibly versatile — they can be pierced, twisted, sculpted, separated, sliced, bonded, welded, cold-linked, and superimposed. Components: Washers, tapping clips, lugs, gaskets, terminals, hinges, and tags. Industries: Nuclear, maritime, pharmaceutical, plumbing, weaponry, jewelry, power, and telecommunications.

For further information, read https://www.custiv.com/service/metal-stamping-services and https://www.esict.com/what-is-metal-stamping/

Machining of unusual materials such as Titanium, Inconel, Kovar, Magnesium, Invar, Hard Steel, and Copper is detailed in this link https://www.custiv.com/blog/inconel-machining.

Brass component manufacturers rely on the alloy’s flexibility to be embellished and polished, its electrical conductivity, impact resistance, durability and opulent appearance. This superb material is also environmentally friendly as it can be recycled with ease.

Design for Manufacturing (DFM) is essential for ensuring product quality, reducing production time, and minimizing costs. Proper DFM considerations help manufacturers achieve consistent results while maintaining structural integrity. When designing brass components: • Avoid sharp edges or abrupt transitions that could lead to stress concentrations. • Maintain uniform wall thickness to prevent uneven cooling or warping. • Incorporate adequate fillet radii at internal corners to improve flow and reduce tool wear. • Include machining allowances (0.25–0.75 mm) based on component size and finish. • Use standardized datum points and tolerances following ASME Y14.5M standards. • Select appropriate brass grades for the operating temperature, load, and environmental conditions. By following these DFM guidelines, designers can reduce post-processing effort, extend tool life, and ensure reliable mass production.

Custom brass component manufacturing represents the perfect blend of precision engineering, material versatility, and sustainability. Through processes such as milling, turning, and stamping, manufacturers can produce components that meet exacting performance standards while maintaining cost efficiency. Whether used in plumbing, aerospace, or electronics, brass continues to prove its value as a durable and adaptable engineering material. At Custiv, we enable manufacturers to achieve excellence in brass machining, stamping, and precision component production through advanced DFM analysis and quality-controlled processes. Partner with Custiv to explore our brass machining and metal stamping capabilities for your next precision project.