Custom metal stamping is, by definition, designed exclusively for a specific part and its functions. Unlike mass-produced stampings, custom metal stamping is chosen when precision and complex dimensions are required to produce a unique part. This process requires the upfront development of a custom metal stamping tool that cuts and forms the part as the metal goes through the stamping press. Custom metal stampings can range from large components for automobiles and custom assemblies to micro-miniature parts for medical devices or electronics.

If you want to learn more, please visit our website Kuasu.

Techniques for Shaping Custom Metal Stampings

Stamping includes a variety of sheet metal forming processes consisting of either a single station operation where every stroke of the press produces the desired form of the metal part or could occur through a series of stages. The following techniques are used to achieve the desired shape in the press.

Bending

Bending creates a formed feature by angular displacement of a sheet metal workpiece. In some processes, one edge of the workpiece is clamped in a stationary position while the other edge is clamped by a metal tool and bent over a form to create a precise bend or shape. Alternatively, the metal piece may be pushed into or against a form.

Blanking

The blanking process removes a metal piece from the primary metal strip or sheet when it is punched through the strip/sheet. The material that is removed becomes the new metal workpiece or blank.

Coining

Coining is a forming process that uses an extreme amount of pressure to push the workpiece into a die. The die then forms the metal into a precise shape and creates permanent forms in the workpiece. Coining also smooths the edges of metal parts by striking them with a high degree of force. This removes existing burrs and hardens the metal. Coining may reduce the need for deburring, grinding, and other secondary processes at the end of the project, which saves both time and money.

Crash/Crush Forming

This process deforms the metal using only a punch and cavity. These dies do not control metal flow and cannot prevent the metal from wrinkling or buckling. They are used to form simple parts, such as brackets and braces, made from thick, stiff metals that are more wrinkle-resistant than thinner metals.

Cutting

One of the most common stamping operations, cutting trims the metal into a part by the use of extremely high force in the stamping press. Cutting operations include trimming, notching, piercing, blanking, lancing, and shearing.

Drawing

A complex drawing die is used to create large metal parts, such as automotive components. The process involves controlling the flow of metal into a cavity via a pressure-loaded draw pad to prevent wrinkling as the material flows over a forming punch.

Embossing

Embossing is a cold-forming process used for creating specific formations or designs on metal pieces. Male and female embossing components press a workpiece between them with sufficient force to form the three-dimensional feature.

Extruding

Extrusion forms the metal inside the diameter of a pierced hole, which may be used for applications such as holding fasteners during part assemblies.

Flanging

The flanging operation bends metal along a curved axis, which may be used to form a projection or the rim of a part as it relates to part assembly and stiffness requirements.

Forming

Metal stamping involves a variety of forming operations. The stamping press forms the metal material by applying tension, compression, or both. The specific type of forming operation selected depends on the material’s properties and the part’s critical dimensions, balancing formability and strength.

Ironing

Similar to the coining process, ironing employs compression to form the part by squeezing the metal along a vertical wall to achieve exact thickness and length dimensions.

Lancing

In order to free up metal without separating it from the metal strip, lancing slices or slits the metal, which may be used in progressive dies as a part carrier.

Piercing

This metal cutting operation, also called perforating, produces a hole in a formed part or sheet metal, which may be round, square or a custom shape. The slug is then discarded.

Pinch Trimming

Pinch trimming is a special method in which the vertical walls of a drawn or stretched vessel are cut by pinching the metal.

Punching

This forming process uses a punch press to force a tool, called a punch, through the workpiece/material to create a hole and produces a scrap slug that is deposited into the die below the sheet metal.

Restriking/Sizing

Used primarily after major forming operations are complete, restriking employs an additional station in the die to finish precision details such as small embossing and sharp radii.

Shaving

An operation used to eliminate or minimize die-break, while maximizing the amount of sheared edge.  The general concept with shaving is to pre-punch the hole slightly smaller, then post-punch the hole to size, using a very tight die clearance. This can also be done on a straight or outside edge.

Shearing

Cutting force is applied perpendicular to the material, causing the material to yield and break.

Trimming

The trimming process achieves the specified profile of a stamped part by forming its perimeter or cutting away excess metal, with precision trimming designed to minimize scrap.

Custom Metal Stamping Production Methods

The method chosen for metal stamping production takes into account the complexity of the part and how metal stamping can best form that part. For precision parts with tight tolerances, the method may include the use of in-die sensors to continually monitor part quality, along with other inspection methods. The method also takes into account secondary operations, such as plating, heat treating, welding, and cleaning or sterilization.

Progressive Die Stamping

Progressive metal stamping is a stamping process that advances a metal strip from station to station performing different operations on the same part in the die until the part is complete. Conical-shaped pilots are inserted into pre-pierced holes in the strip to ensure the precision of the alignment as the part advances to guarantee the accuracy of the finished product. Since the part is attached to a metal strip throughout its formation, the entire process and parts will be out of tolerance if the strip is off by even a tiny fraction of an inch.

Progressive die stamping offers some advantages such as being a highly repeatable process and since the material is continuously fed into the stamping press, long production runs can be completed, producing more finished parts in less time resulting in lower cost per part.

Progressive Stamping Delivers High Speed Production and Lower Costs.

Transfer die stamping

Transfer die stamping uses one press to operate multiple tools. The part is removed from its metal strip so that it can be freely transferred.  A part, which can be turned or rotated, is shaped by each station until it is complete. Automation of the transfer process streamlines the operation into a single press.

Transfer dies can handle many part features in one press pass, such as holes, cut-outs or threading, which can eliminate costly secondary operations.

Transfer die stamping is typically used for large parts like frames, tube applications, draws, shells, and structural components.

Is Progressive Die Stamping or Transfer Die Stamping Best for Your Next Precision Metal Stamping Project?

Deep Drawing

Beneficial for applications requiring recessed cavities, where the depth of the drawn part exceeds its diameter, deep drawing uses blanking, swaging or sizing to deform the base material and apply recessed features.

Fine Blanking

Fine blanking is optimal for parts that require very smooth, precise edges or exceptional flatness. Fine blanking is particularly suitable for moving parts such as gears. Fine blanking is a combination of metal stamping and cold-metal extrusion techniques, requiring special presses. 

Progressive Stamping vs. Fine Blanking: Three questions OEMs Should Ask

Multi-slide / Four-slide Stamping

Multi-slide / Four-slide stamping is best suited for fabricating complex components that have numerous bends or twists and for forming wire. The difference between multi-slide and four-slide is that four-slide metal stamping machines have four moving slides while multi-slide machines have more than four slides. The slides or rams in the machines strike the material to produce the finished parts.

Multi-slide / Four-slide equipment can manufacture complicated parts with multiple, complex, or over 90° bends and twists including clips, brackets, flat springs, terminals, retainers, and wire formed parts. Both flat and round materials can be formed.

L E A R N    M O R E 

A key factor in the success of a precision stamped part is specifying the best metal for the process and the application, ranging from lightweight aluminum to heavy-duty steel to high-cost precious metals. OEM engineers can benefit by consulting metal stamping specialists early in the part design phase to evaluate how metal stamping can work and the exact material specifications needed for the application at hand. 

Material selection involves evaluating:

• The properties of the metal
  • tensile strength
  • elasticity
  • conductivity
  • heat capacity
  • corrosion resistance
  • weldability
  • machinability
  • formability
• The thickness and width of the material
•  How well metal stamping can form to specifications with that material
• How the part will perform in the application and operating environment
• The material’s cost and availability

Typical Materials Used For Precision Metal Stampings

Some of the most commonly used materials for precision metal stamped parts include:

Steel

Carbon steel is one of the most popular materials used in metal stamping, which can take on many different forms, properties and finishes, offering optimal strength, performance and cost-effectiveness. Each year, steel production exceeds 1.3 billion tons worldwide. Basic steel is magnetic material. With the addition of chrome and nickel to make stainless steel, it loses its magnetic properties.  Many different types of steel may be used including hot and cold rolled steel; stainless steel; high-tensile steel; low, medium and high carbon steel; and spring steel.

Aluminum

Aluminum offers many advantages for metal stamping applications. Aluminum has the highest strength-to-weight ratio of any metal. Aluminum conducts electricity better than copper and is non-magnetic. For companies seeking sustainability, aluminum is 100% recyclable without losing any of its natural characteristics. However, aluminum can be abrasive in tooling and is more expensive that steel.

Copper

Copper that is suitable for metal stamping comes in many forms, including such alloys as aluminum clad copper, brass, phosphor bronze, beryllium copper and aluminum alloys. Copper is often selected for stamped components and conductors for electronic devices, as well as electrical wiring, heating and plumbing, and other applications that require its extremely high electrical and thermal conductivity. Copper also resists corrosion while maintaining an attractive appearance. The softness of copper makes it one of the best metals for stamped parts.

Brass

With its reasonable price and flexibility, brass can work for almost any function in metal stamping. As an alloy of copper, brass can easily be soldered to copper. Brass is highly resistant to corrosion and will not rust. It is also effective in carrying electrical current while dealing with high stress very well.  As a result of its unique properties, brass is one of the most-used metal materials in the world.

Titanium

Titanium is known for its corrosion resistance and high-impact toughness. Titanium is very expensive to manufacture but has the highest strength to density ration of any metallic element. It is often used in aerospace structures and implantable medical devices.

Precious Metals

Precious metals may be used as a plating or coating on stamped parts to increase conductivity or to add strength and corrosion resistance to the finished products. In metal stamping, designing a process that conserves the precious metal is critical, due to its high cost and limited availability in some cases. Manufacturers in the automotive, electronics, telecommunications and medical device industries are among the leading users of precious metals such as gold and palladium in critical parts.

Nickel Alloys

Nickel alloys resist high pressure and maintain their properties under extremely high temperatures. They also offer high strength and toughness and excellent resistance to atmospheric corrosion. High nickel alloys are perhaps the most frequently used material for metal stamping production among the hundreds of specialty alloys used in the industry.

Metal Stamping Materials by Industry

Each industry favors particular metals for their precision metal stampings, due to their unique applications and the environmental and operating conditions that the parts must withstand. For example, stamped parts for the automotive industry must be able to hold up under extreme heat and cold, as well as contact with a variety of liquids, while medical devices require high sanitation and safety standards, and electronic parts require electrical conductivity.

Automotive

• Red Metals including Copper, Bronze and Brass
• High-Strength, low-alloy Steel

Medical Device

• Stainless Steel
• Titanium
• MP35N
• Platinum Iridium
• Niobium
• Tantilum
• Aluminum
• Copper
• Custom shaped wire

Electronics

• Mill hard or post heat-treated Beryllium Copper
• Phosphor Bronze and a wide array of high-performance alloys
• Aluminum Clad Copper
• Custom shaped wire

Insert Molding

• Brass and high-performance copper-based alloys
• Pre-plated ferrous and non-ferrous alloys
• Aluminum clad copper
• Custom shaped wire

L E A R N    M O R E 

Production of precision metal stampings involves a complex process that begins with design collaboration between the stamper’s and the manufacturer’s engineers. Software simulations are often followed by developing a prototype tool to produce sample parts. Full production planning takes into account every step of the process from custom tool design and stamping through finishing and assembly/packaging to ensure that all critical specifications are met, with quality control from start to finish.

Design Engineering Assistance

Metal stamping engineers can offer solutions for cost-effective part design and production upfront during the estimating process, as they review the part design, prints and material specifications. Using advanced technology, such as 3D CAD, metal stampers can test design options and recommend improvements to reduce failure risk and increase functionality, while meeting all critical specifications and quality standards.

Want more information on Custom Stamping Dies? Feel free to contact us.

Prototyping

With the development of new custom stampings, it can pay to test and analyze small quantities of stampings before investing in full production. By building a prototyping tool to run sample parts and using simulation software to evaluate how the part and material will function in the tool, the metal stamper can identify and correct potential weaknesses prior to production, which saves on development costs and time to market. The stamper may recommend specialized tool functions, such as progressive dies or in-die assembly, to improve manufacturability.

Production Planning

Collaboration between the manufacturer's technical staff and the metal stamper's engineers in the initial planning stage is key to ensuring efficient production and long-term functionality of the part. In-depth planning sessions allow for review of:

• part specifications
• industrial applications/operating environment
• industry and statutory/regulatory requirements
• industry quality standards (i.e. APQP, DQ/IQ/OQ/PQ)
• unusual risks
• material characteristics
• required secondary operations
• tooling parameters
• control plans
• final assembly/packaging requirements
• demand variances

For manufacturers in the planning process for new products, the technical team of the precision metal stamper can add valuable guidance upfront to help speed time to market.

A designated project manager is responsible for ensuring the project is completed on time and on budget and for communicating status updates to the cross functional team. 

Tool Design, Build and Maintenance

Tool designers review technical specifications and provide critical feedback for tool design. Once designs are approved, highly complex, high-precision tools are built, often including in-die sensors to ensure tool safety and consistent quality. Tooling experts conduct preventative maintenance to ensure tools last the duration of the program with little or no downtime.

Precision Metal Stamping

Sophisticated technology is used for high-speed, precision metal stamping, with a variety of presses that are augmented with advanced features such as electronic servo feeds, robotics, and real-time quality control. Multiple operations like in-die tapping, in-die fastener insertion and in-die assembly can be performed in the stamping press, which can eliminate the need for those secondary operations.

Secondary Operations

Secondary operations are often required to fully finish the metal stamped part for seamless integration into a product or system. Parts may need to be trimmed or welded. Finishing techniques such as coating, plating, polishing or deburring may be chosen to inhibit corrosion, improve appearance, or smooth sharp edges. Metal stampers provide many services in-house, such as cleaning and custom assembly, and also coordinate with approved suppliers for specialized metal finishing services, such as welding or electropolishing.  

Assembly and Packaging

Metal stamping engineers evaluate assembly and packaging needs in the production planning phase to ensure finished parts are ready for further production or shipment when delivered to the manufacturer. Parts may be shipped fully assembled or as sub-assemblies and packaged based on manufacturer specifications (i.e. reel-to-reel, loose piece, on a bandolier).

Quality Control

Precision metal stampers apply mistake-proof processes that incorporate quality controls into every phase of a metal stamping project. Company-wide information sharing systems ensure quality commitments are understood and implemented by every project team member. Sophisticated quality control technology is leveraged throughout the process to ensure zero defects, such as in-die sensors, real-time statistical process control, and optical vision systems.

L E A R N    M O R E 

The Solid 6 Types of Stamping Dies

Metal stamping is the backbone of modern manufacturing. It helps create precise, high-quality components for everyday products. Stamping dies are key in shaping metal into functional forms, from automotive parts to consumer electronics. 

However, selecting the right die type is crucial because it directly impacts production efficiency, quality, and costs. 

If you've been wondering which stamping die is best suited for your needs or how to optimize your operations by leveraging stamping technology, in this article, we will explore the following:

• Different types of stamping die
• Their applications
• Factors that should guide your choice
  
  

Types of Stamping Dies

Whether dealing with small batch runs or high-volume production, understanding the six common types of metal stamping dies can help you select the best technique for your next project:

1. Single station dies
2. Blanking dies
3. Piercing dies
4. Compound dies
5. Multi station dies
6. Transfer dies
   
   

1. Single Station Dies

Single-station dies are designed to perform a singular operation with each press stroke. They are typically used for straightforward tasks such as cutting materials into specific shapes or punching holes in a workpiece. They offer a focused approach to material processing.  

The simplicity of single-station dies makes them easy to design, set up, and operate, which makes them ideal for small production runs or pilot projects. This straightforward design facilitates quick troubleshooting and adjustments, allowing for flexible manufacturing solutions.  

Despite their benefits, single-station dies can be inefficient for large production volumes, as each operation is performed one at a time. This limitation can slow production and increase labor costs, especially for complex parts requiring multiple operations. 

2. Blanking Dies

Blanking dies are specialized tools designed to cut a piece of material, known as a "blank," from a larger metal sheet. These blanks are the foundational shapes for producing complex part designs.

Blanking dies' primary advantage is their ability to produce clean, precise cuts, which makes them well-suited for high production volumes. Additionally, they minimize material waste, which is both cost-effective and environmentally friendly.  

A common challenge with blanking dies is the potential for edge contractions, which can require additional post-processing to achieve a smooth finish. This step adds complexity to the manufacturing workflow and may impact overall efficiency.  

3. Piercing Dies

Piercing dies cut holes into metal sheets, creating gaps, slots, or openings. They are often used in conjunction with other dies for multi-stage projects, providing versatility in design and application.  

A key feature of piercing dies is their ability to produce crisp, burr-free openings, making them invaluable for high-precision applications. Their precision is beneficial in industries where accuracy is highly important, such as aerospace and automotive manufacturing.  

Frequent tool maintenance may be required due to wear from piercing operations, especially when working with thicker or more challenging materials. This maintenance requirement can increase downtime and affect productivity.  

Resource: Stay on top of your tool maintenance, 

learning how to maintain the life of them here

4. Compound Dies

Compound dies are engineered to perform multiple operations simultaneously in a single stroke, such as cutting and punching. Each action occurs in one press cycle, enhancing efficiency and reducing manufacturing time.  

These metal stamping dies are commonly used for tasks requiring high-speed metal stamping accuracy, such as producing parts for electronics or medical equipment. Their ability to perform complex operations makes them valuable in these specific types of precision manufacturing.  

While compound dies offer improved efficiency, they can be expensive to design and produce due to their complexity. As a result, they are best suited for high-volume, high-precision production runs where their cost can be justified.  

5. Multi Station Dies

Multi station dies, also known as progressive stamping dies, are designed to perform multiple operations across several stations in a single press cycle. As the material feeds through each stage, it undergoes successive operations like cutting, punching, and bending until the final part is complete.  

These dies are key for industries producing high volumes of consistent parts, such as the automotive and aerospace sectors. Their ability to streamline production processes makes them a preferred choice for high-demand applications.  

Despite their efficiency, progressive stamping dies require advanced press systems and skilled operators to ensure seamless functionality. This increases upfront costs and necessitates specialized training. Outsourcing to an experienced progressive die stamping company can help alleviate these upfront costs by providing access to pre-trained expertise and advanced equipment.

6. Transfer Dies

Transfer dies move individual stamping die components from one station to another, with each station performing an independent action on the part. This setup allows specialized operations at each stage and accommodates complex part designs.  

They are ideal for larger, more complex parts that require distinct operations at each station. This flexibility makes them suitable for customized manufacturing needs.  

However, transfer systems can be slower than progressive setups, making them less suitable for jobs requiring rapid throughput. This limitation can affect turnaround times and overall production efficiency.

Key Considerations in Die Selection

Selecting the right die can help with efficiency and cost-effectiveness in manufacturing. You can optimize your production process by considering the following:

• Match production volume
• Part complexity
• Material properties

Match Production Volume 

When choosing your die, it is best to consider both the production scale and the parts' complexity. 

For low-volume production, simpler dies, such as single-station or blanking dies, are cost-effective and easy to set up, minimizing production overheads. 

High-volume requirements benefit from sophisticated tools such as progressive stamping dies, which improve turnaround time and reduce per-unit costs. The choice of die largely depends on your batch size.

Part Complexity 

Basic dies such as blanking or piercing are ideal for simpler designs and straightforward components like flat panels or single-hole parts. These dies are efficient and cost-effective, providing precision for straightforward projects without complex manufacturing processes. Blanking dies cut flat shapes from sheet metal, while piercing dies create holes, ensuring that parts are produced with clean, accurate edges.

On the other hand, compound or progressive dies are best needed for complex geometries, such as multi-dimensional or intricate components. Compound dies are suited for operations where multiple actions overlap in a single stroke, making them perfect for producing detailed parts that require precise alignment in one cycle.  Progressive dies, meanwhile, are designed for high-volume production and perform a series of operations at different stages within the die. 

These dies are ideal for intricate shaping, cutting, and forming projects. They allow for efficient mass production without compromising quality. By choosing the appropriate die type, manufacturers can ensure that the project's intricacies are met effectively without incurring unnecessary costs.

Material Properties 

Due to their malleability, softer materials like aluminum are compatible with standard dies. This allows smooth and efficient stamping processes. These materials require less force, reducing wear and tear on the dies, making standard options practical and cost-effective. 

Contrarily, harsher metals like stainless steel demand stronger and more wear-resistant dies. These materials' hardness and strength necessitate specialized dies that can withstand the increased stress and potential for abrasion during stamping. 

Additionally, the thickness of the material is a key factor. Thicker materials can significantly increase the pressure required during the stamping process. Often allowing custom die designs. These custom dies are tailored to manage the added pressure and ensure precise and effective stamping without compromising the integrity of the die or the material.

Choose the Right Stamping Die for Your Needs

Stamping dies are at the heart of modern manufacturing. They offer precision and efficiency in shaping metal into functional parts. 

Choosing the right stamping die for your project isn’t just about picking a tool—it’s about aligning your production goals with the die's capabilities. Each type serves a unique purpose, from single-station simplicity to progressive die efficiency.

Basic dies, like blanking or piercing, are excellent for straightforward tasks. However, if your project involves intricate geometries or high-volume production, progressive or compound dies might be the better choice. Also, don’t forget the material—tougher metals require specialized, wear-resistant dies to maintain precision and reduce tool wear.

Contact us to discuss your requirements of sheet metal embossing dies. Our experienced sales team can help you identify the options that best suit your needs.

Ready to Explore the Possibilities?