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Core products engineered for next-generation energy systems
As the global energy sector undergoes its most dramatic transformation in over a century — pivoting from fossil fuels toward solar, wind, hydrogen, and battery storage — the demand for ultra-pure, high-conductivity conductive materials has surged to unprecedented levels. Oxygen Free Copper (OFC) bars, defined by their oxygen content below 0.001%, have emerged as the critical conductor of choice across virtually every clean-energy application.
Unlike standard electrolytic tough-pitch copper, oxygen free copper bars eliminate internal micro-void formation caused by hydrogen embrittlement, delivering exceptional electrical conductivity (≥101% IACS), superior thermal stability, and outstanding corrosion resistance. For renewable energy systems — where reliability over 25–40 year operational lifespans is non-negotiable — these properties translate directly into energy yield, system safety, and total cost of ownership.
The global oxygen free copper market was valued at over USD 3.8 billion in 2024 and is projected to exceed USD 6.5 billion by 2030, propelled almost entirely by green energy buildout and electrification mega-trends. China, Germany, the United States, and India represent the four largest demand centers, collectively accounting for over 65% of global OFC bar consumption.
Oxygen free copper bars consistently achieve conductivity exceeding standard copper benchmarks, minimizing resistive losses in high-current renewable energy circuits.
Eliminates hydrogen embrittlement and micro-porosity — essential for welded bus bars in solar inverters and battery management systems.
Maintains mechanical integrity under continuous thermal cycling — a critical requirement in grid-scale energy storage and EV fast-charging infrastructure.
Corrosion-resistant OFC bars match the projected operational lifespans of modern renewable energy installations, reducing lifecycle replacement costs.
Key forces driving global OFC demand in the clean energy era
Global solar PV capacity is projected to triple by 2030. Each gigawatt of utility-scale solar requires approximately 3,500 tonnes of copper, with OFC bars preferred for inverter bus bars, DC combiner boxes, and junction blocks due to zero oxygen-related solder fatigue.
Offshore wind turbines — operating in aggressive saltwater environments — increasingly mandate oxygen free copper bus bars for generator winding terminals and power conversion systems, where conventional copper would suffer accelerated corrosion-induced conductivity loss.
Battery Energy Storage Systems (BESS) from 100MWh to multi-GWh scale rely on OFC bars as the primary current-carrying medium for cell interconnects, module bus bars, and DC switching infrastructure — where purity directly impacts charging efficiency and cycle life.
Ultra-fast EV chargers (350kW+) and on-board battery management systems require OFC bus bars capable of sustaining peak current densities exceeding 10A/mm². China's EV production reached 9.5 million units in 2024, driving unprecedented demand for precision OFC bars.
Proton Exchange Membrane (PEM) electrolyzers — the core technology for green hydrogen production — use OFC bars as bipolar plate current distributors and electrode bus connections, demanding the highest possible conductivity and chemical inertness.
High-Voltage Direct Current (HVDC) transmission systems connecting offshore renewables to inland grids require oxygen free copper bus bars rated for continuous operation at elevated temperatures, with stringent requirements for low electrical resistance over multi-kilometer runs.
Oxygen Free Copper Bar across the renewable energy value chain
In utility-scale solar plants, OFC bars serve as the primary low-inductance bus connecting string inverters to central transformers. Their zero-void microstructure eliminates partial discharge at high DC voltages (up to 1500V), while superior thermal conductivity ensures stable operation at ambient temperatures exceeding 60°C in desert installations. Custom-profiled OFC bus bars reduce installation labor by up to 40% compared to cable assemblies.
Modern multi-MW wind turbines deploy OFC bars within the nacelle power converter — bridging the generator output rectifier and grid-side inverter. The vibration-intensive environment demands OFC bars with excellent fatigue resistance, while sub-zero to +80°C thermal cycling requires materials with low differential thermal expansion at junction interfaces. OFC bars also serve as grounding conductors in lightning protection systems.
In EV battery packs and stationary BESS, laser-welded OFC bus bars connect individual cell terminals to module rails. The absence of oxygen prevents weld porosity — a critical safety factor at weld points that must withstand 2000+ charge cycles. OFC bars enable thinner cross-sections for the same current rating, reducing pack weight by up to 8% compared to standard copper alternatives.
350kW+ DC fast chargers require OFC bus bars rated for sustained 800A+ current flows. The combination of ≥101% IACS conductivity and superior heat dissipation allows designers to use more compact bus bar profiles, reducing cabinet size while maintaining safe conductor surface temperatures below 75°C — the threshold for UL and IEC certification compliance.
Floating offshore wind platforms, tidal turbines, and wave energy converters operate in environments with extreme humidity, salt spray, and biological fouling. OFC bars with passivated surface treatments provide up to 3× the corrosion resistance of standard copper, ensuring electrical integrity in subsea junction boxes and offshore substation switchgear over 20+ year deployments.
In PEM electrolyzers producing green hydrogen, OFC bars carry the massive DC current (tens of thousands of amperes in industrial-scale stacks) from rectifier banks to electrode assemblies. Any oxygen contamination in standard copper bars can catalyze undesirable electrochemical reactions, compromising hydrogen purity. OFC bars are therefore specified as mandatory in ISO 22734-compliant electrolyzer systems.
Sichuan Kepai New Material Co., Ltd.
Sichuan Kepai New Materials Co., Ltd., established in 2017, is a high-tech enterprise integrating research and development, production, and sales. Currently, the factory covers an area of approximately 9,000 square meters, with an office space of about 1,000 square meters. The company primarily engages in the production of strategic emerging new materials for the national 13th Five-Year Plan, including special copper alloys such as tellurium copper, high-conductivity oxygen-free copper, silver copper, and dispersion copper, while also focusing on the research and development of high-conductivity, easy-to-machine, high-strength copper alloys. The products are mainly applied in high-tech fields such as new energy vehicles, 5G technology, laser cutting, and lithium battery relays.
The company is located in the western area of the Sichuan Guanghan Industrial Development Zone, adjacent to National Highway 108, boasting a superior geographical location and convenient transportation, which lays a solid foundation for the rapid development of the enterprise. Since its establishment, Kepai has adhered to the business philosophy of "innovation-driven development, quality wins the market," committed to providing customers with the highest quality high-end copper alloy materials, and promoting industrial upgrading and sustainable development.
Technological innovation is the core competitiveness of Sichuan Kepai New Materials Co., Ltd. The company has a research and development and production team composed of senior industry experts who keep pace with international cutting-edge technology trends and continuously explore the unknown boundaries in the field of new copper alloy materials. Through a combination of independent research and development and industry-university-research collaboration, Kepai has made breakthrough progress in several areas, including high-performance tellurium copper, lead copper, and sulfur copper. Many of its technological achievements have reached international advanced levels and have been successfully applied in various industries such as new energy vehicles, precision machining parts, plasma cutting, relays, and energy storage, earning widespread recognition and praise in the market.
Kepai's product line is rich and diverse, covering a comprehensive range of solutions from basic materials to high-end customization. We focus on providing customers with high-performance, high-quality high-end copper alloy products, including but not limited to pure copper, oxygen-free copper, oxygen-free high-conductivity tellurium copper, nickel tellurium copper, tin bronze, beryllium copper, lead bronze, sulfur copper, and chromium zirconium copper. These products play an important role in reducing production costs and enhancing product performance due to their excellent physical and chemical properties and environmental friendliness, creating significant economic and social benefits for customers.
In the face of global market competition, Sichuan Kepai New Materials adheres to the development strategy of "rooted in Sichuan, radiating nationwide, and moving towards the world." By continuously optimizing market layout and improving the sales network, we have established a stable customer base in multiple provinces and cities across the country and have formed long-term cooperative relationships with several internationally renowned enterprises. At the same time, the company actively expands into overseas markets, participates in international competition and cooperation, and strives to promote Kepai's brand influence on the global stage.
We understand that the long-term development of an enterprise is inseparable from an excellent corporate culture. We advocate the corporate spirit of "integrity, innovation, collaboration, and win-win," encouraging employees to explore boldly and innovate courageously, while also emphasizing teamwork and talent cultivation, striving to create a harmonious, open, and inclusive work atmosphere. We believe that only by continuously pursuing excellence and creating value can we win the trust of customers and the respect of society.
State-of-the-art production & testing facilities for oxygen free copper bar manufacturing
Smelting
Laying-off
Extrusion
Drawing
Straightening
Package
Eddy Current Conductance Instrument
Chemical Composition Test Room
Metallographic Sample Polishing Machine
Microcomputer Controlled Electro-Hydraulic Servo Universal Testing Machine
Liquid Crystal Display Electronic Universal Testing Machine
Hardness Tester
Quality certifications and global market presence
Looking ahead, Sichuan Kepai New Materials Co., Ltd. will continue to uphold its original intention, with even greater enthusiasm and determination, to engage in research and application in the field of new materials, contributing to the development of the new copper alloy materials industry in China and globally. We look forward to working hand in hand with friends from all walks of life to create a brilliant future together!
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