Copper Braid Jumpers, Lugs, Links & Bonding Straps -

Carsai manufactures custom copper braid jumper products for electrical equipment, transformers, switchgear, busduct systems, cable trays, enclosures and industrial grounding applications.

A braided jumper uses fine copper wires woven into a flexible conductor. It maintains electrical continuity while accommodating vibration, thermal expansion, movement and minor terminal misalignment.

Our products include:

Flexible copper braid jumpers
Copper braided bonding jumpers
Braided grounding jumpers
Copper braid with lugs
Press-welded braided links
Bare and tinned copper jumpers
Ring-, fork- and plate-terminal assemblies
Single-hole and multi-hole terminals
Custom lengths and copper cross-sections
Insulated and uninsulated flexible links

Products are manufactured according to customer drawings, samples and installation requirements.

For our complete braided conductor range, visit our Copper Braid Manufacturer page.

Custom tinned copper braided grounding straps with punched terminals for electrical bonding applications

What Is a Copper Braid Jumper?

A copper braid jumper is a short flexible conductor used to bridge two nearby electrical terminals or conductive components.

Flexible Copper Braid Jumpers

Flexible copper braid jumpers are commonly used where equipment may move, vibrate or expand during operation.

They can accommodate:

Hinged-door movement
Transformer vibration
Thermal expansion
Cable-tray movement
Pipe and flange displacement
Minor terminal misalignment
Assembly tolerance

The phrases braided flexible copper jumpers, copper braided flexible jumpers and flexible copper braided jumper describe similar custom braided connectors.

Common applications include:

Electrical cabinets
Transformer terminals
Switchgear
Circuit breakers
Cable trays
Busbar sections
Equipment frames
Battery systems
Pipe flanges
Moving machinery

The jumper should have enough flexible length to move without being stretched tightly or repeatedly bent directly beside the terminal.

Copper Braided Bonding Jumpers

A copper braided bonding jumper electrically joins two conductive parts so that continuity is maintained between them.

Related phrases include:

Bonding jumper flexible copper braid
Flexible copper braided bonding jumper
Braided copper bonding jumper
Flexible bonding braid
Copper braid bonding link

Typical bonding applications include:

Cabinet doors and frames
Separate enclosure panels
Cable-tray joints
Pipe flanges
Machinery mounted on vibration isolators
Transformer tanks
Removable covers
Painted metal assemblies

A bonding jumper may bridge a mechanical connection that does not provide reliable metal-to-metal electrical continuity.

The equipment or grounding-system designer should specify the required conductor cross-section and applicable installation requirements.

Braided Grounding Jumpers

A braided grounding jumper connects equipment or a conductive assembly to a grounding path.

The same basic braid construction may be used for both grounding and bonding, but the electrical function is different:

Grounding connects equipment to the grounding system.
Bonding joins conductive parts to maintain electrical continuity.

Braided grounding jumpers may be installed on:

Electrical enclosures
Machine frames
Transformer housings
Generator frames
Switchboard doors
Cable trays
Busbar supports
Industrial equipment panels

Copper Braided Links

Copper braided links are flexible connections used between electrical terminals, busbars or equipment sections.

A braided link can carry:

Normal operating current
Intermittent current
Grounding or bonding current
Short-duration fault current when appropriately designed

Copper braided links can be manufactured as:

Straight flat links
Curved jumpers
U-shaped connectors
Offset links
Parallel braid assemblies
Links with different terminals at each end

The complete current and movement requirements should be provided before the conductor size is selected.

Copper Braid with Lugs

A copper braid with lug is supplied as a completed assembly with mounting terminals attached to the braid.

The term copper braid lug may refer to:

A ring lug attached to copper braid
A fork terminal
A flat copper plate
A press-welded braid end
A custom multi-hole terminal

Available end configurations include:

Ring lugs

Ring terminals surround the mounting bolt and provide a secure connection for equipment grounding and bonding.

Fork lugs

Fork terminals allow installation or removal without completely removing the mounting bolt.

Flat copper terminals

Flat plates can provide wider contact areas and support one-hole, two-hole or multi-hole mounting patterns.

Press-welded ends

The braid itself is compressed and welded into a solid terminal area, eliminating the need for a separate lug.

The two ends can use different terminal types when required by the installation.

Tinned Copper Braided Jumpers

A tinned copper braided jumper uses tin-coated copper braid, tin-plated terminals or a completely plated finished assembly.

Tin plating can provide:

Better resistance to copper oxidation
More consistent terminal surfaces
Protection during storage and shipment
Suitability for humid environments
Compatibility with tinned mating terminals

Tin remains electrically conductive and should not be confused with insulation.

A tinned jumper may be produced from:

Pre-tinned copper wires
Bare copper braid followed by plating
Tinned braid with bare copper terminals
A fully tin-plated completed assembly

The required plating thickness and coverage should be identified on the drawing.

Press-Welded Jumper Ends Versus Separate Lugs

Braided jumpers can use press-welded ends or separate terminal components.

Terminal structure	Main characteristics
Press-welded end	Compact solid terminal formed directly from the braid
Copper terminal plate	Suitable for wide or multi-hole connections
Ring lug	Common for grounding and smaller mounting points
Fork lug	Convenient for removable connections
Parallel-braid plate	Allows several braids to share one large terminal

Press-welded terminals are useful for compact custom components.

Separate copper plates may be better when the assembly requires:

Large terminal areas
Several mounting holes
Thick terminal sections
Different terminal geometry
Several braids in parallel

Jumper Length and Flexibility

The overall jumper length should be selected according to the installed distance and expected movement.

A jumper that is too short may:

Pull on equipment terminals
Bend sharply beside the lug
Transfer vibration
Fatigue near the terminal transition
Be difficult to install

A jumper that is unnecessarily long may occupy additional space or interfere with adjacent components.

The drawing should specify:

Overall length
Terminal-to-terminal distance
Flexible braid length
Installed bend or loop
Required movement direction
Minimum surrounding clearance

Conductor Size and Current Capacity

The external width and thickness of copper braid do not equal a solid copper cross-section because spaces exist between the individual wires.

Electrical sizing should consider:

Actual metallic copper area
Overall conductor length
Continuous current
Peak or fault current
Duty cycle
Ambient temperature
Cooling and airflow
Terminal contact resistance
Insulation coverage
Allowable temperature rise

For grounding and bonding jumpers, the system designer should specify the required conductor size according to the application and applicable requirements.

A large braid can still perform poorly if:

The terminal is undersized
Contact surfaces are contaminated
Bolt pressure is insufficient
The mounting hole is too close to the terminal edge

Custom Manufacturing Options

Carsai can manufacture custom jumper assemblies with:

Flat or round copper braid
Bare or tinned copper
Custom metallic cross-section
Press-welded ends
Ring or fork lugs
Solid copper terminal plates
Single- or multi-hole terminals
Slotted mounting holes
Angled or offset terminals
Parallel braided conductors
Heat-shrink or flexible sleeves
Product markings
Prototype and production quantities

Information Needed for a Quotation

Please provide:

Jumper, bonding or grounding application
2D drawing or dimensioned sketch
Flat or round braid
Bare or tinned copper
Copper cross-sectional area
Overall and flexible length
Lug or terminal type
Hole diameter and spacing
Continuous or fault current
Expected movement
Insulation requirement
Prototype and production quantities

An existing sample can support the initial review, but a dimensioned drawing is recommended for repeat production.

Frequently Asked Questions

What is the difference between a copper braid jumper and a braided link?

The terms often overlap. A jumper usually bridges two nearby terminals, while a link is a broader term for a flexible electrical connection.

Can copper braid jumpers be supplied with lugs?

Yes. Ring, fork, flat-plate and custom terminals can be fitted to the braid.

Can the two ends use different terminals?

Yes. Each end can have a different lug, hole size, plate shape or mounting orientation.

Are tinned braided jumpers insulated?

No. Tin plating is conductive. A separate heat-shrink or flexible sleeve is needed for insulation.

Can several braids be installed in parallel?

Yes. Multiple braids can be joined to common terminal plates when additional copper cross-section is required.

Can you manufacture from an existing sample?

Yes. Samples can support product review, but a dimensioned drawing is preferred for repeat orders.

Request a Copper Braid Jumper Quotation

Carsai manufactures custom copper braid jumpers, bonding links, grounding straps and lugged flexible connectors for industrial electrical equipment.

Send your drawing, braid cross-section, length, terminal design, hole pattern, finish, insulation and required quantity.

Request a custom copper braid jumper quotation based on your drawing, sample or dimensional specification.

Get a Quote