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Precision Metal Stamping

What is metal stamping and why should you choose this over other metal forming methods? The metal stamping process offers a variety of part products depending upon the needs and complexities of different industries. So, it is essential to understand all the technicalities of metal stamping to choose the right metal stamping manufacturer for your business.

What is Metal Stamping

Metal stamping is a metal forming process that cuts or forms the metal pieces to give them the desired shape. From a piece of fine jewelry to a large metal washer, the metal stamping process is used to create an extensive range of products in the manufacturing industry.

Precision metal Stamping

During the metal stamping process, a metal piece is placed in between the stamping dies and pressing is done to give the workpiece the desired shape. Generally, cold metal is used in this process, however, in some cases, heated metal is also used.

For the flexibility it provides, metal stamping has become an ideal manufacturing process for various industries. Accuracy is also a big advantage of the metal stamping process. It can produce a high volume of identical parts with the exact specifications. And, that is the reason, metal stamping is preferred over other metal shaping processes.

Basics of Metal Stamping

Metal stamping is also known as metal pressing. The sheet metal is used in coil or blank form in the press. Die tooling is the core step in this process. Before starting the metal stamping process, the tooling is designed by using CAD/ CAM technology.

CAD/ CAM technology

To achieve the best quality finished part, it is essential that die clearance is maintained in an optimum manner. Thinner the material, tighter clearance would be needed. So, the design process is complex in nature and may take a long time.

Punching, lancing, bending, drawing, flanging, coining, and embossing are some of the stamping techniques that are used to get the desired finished part. Multiple of these steps are performed depending upon the shape needed in the finished part.

Types of Metal Stamping Processes

Some commonly used types of metal stamping process are:

  • Precision Metal Stamping
  • Progressive Die Stamping
  • Hot Metal Stamping
  • Transfer Die Stamping
  • Four Slide Stamping

Now let’s check each one of them in detail.

Precision Metal Stamping

Precision metal stamping is a metal forming process that produces cost-effective precision metal parts quickly. With the growing demand for precision metal parts in manufacturing, this stamping process is used to produce a variety of products in multiple industries. Precision metal stamping can give various custom shapes to flat sheet metal.

Progressive Die Stamping

As the name suggests, in progressive die stamping a metal coil is fed through a press that consists of a series of stamping stations. All these stations perform a different action on the metal piece. The finished piece is cut from the strip at the last stamping station. This type of stamping produces minimal scrap during the process.

Hot Metal Stamping

In simple words, hot metal stamping is the process of forming a metal workpiece using extreme heat and cooling it immediately after that. This process is used to convert low tensile strength metal to a very high strength and lightweight steel part. You can produce complex parts altogether. However, it is difficult to cut the hardened part.

Transfer Die Stamping

A transfer die is similar to a progressive die; however, it is transferred from one stamping station to the other by a mechanical transport system. Transfer die stamping is cost-effective and is mainly used to perform operations on parts free from the strip.

Four Slide Stamping

Four slide stamping is generally used to produce complex components with multiple bends. This is a multipurpose stamping process where you can attach a separate tool in each slide. Instead of vertical slides, it is aligned horizontally to shape the metal piece. A high volume of complex pieces can be produced as multiple steps like bending, cutting, etc. can be performed in one single process.

Materials Used in Metal Stamping

The type of material used in the metal stamping process is crucial to decide how much force is needed to cut and give it the desired shape. Some of the common types of metals fabricated through this process are:

Precious Metals: Gold, silver, and platinum. This type of metal is expensive.

Ferrous Metals: Iron-based alloys, such as stainless steel. Low cost and lower unit production prices make them the most commonly used in stamping operations.

Non-Ferrous Metals: Bronze, brass, and zinc.

Specialty Metals: Titanium and nickel. This type of alloy is tailor-made for specific applications.

Different Steps in Metal Stamping

A metal may go through different stages of cutting and forming like:

Punching: Punching creates a hole in the flat materials like sheet metals via shearing and removes a scrap slug from the metal piece. This process is used to produce holes of various shapes quickly.

Blanking: During blanking cut, a metal workpiece is removed from the primary metal sheet. The rest of the metal is set aside.

Lancing: Lancing is generally used during progressive stamping, in which small cuts are created in the metal. This gives greater flexibility to the metal.

Bending: As the name suggests, the bending process folds a metal along a straight axis to give it different shapes. This process is used to create the most finished products in metal stamping.

Coining: The coining process is used in precision stamping. Very high press is given to the metal to get a finished part with crisp edges.

Drawing: Drawing uses tensile forces to stretch metal into thinner form to give it the desired thickness and shape.

Embossing: Embossing is used to create raised or sunken designs and images on metal surfaces.

Flanging: Flanging is like bending that folds a metal along an axis. However, instead of straight-line, it bends the metal in 90 degrees.

Shearing: Shearing is used to cut a metal along a straight line. This metalworking method is best for producing rectangular or square large blanks of sheet metal.

Trimming: This is a finishing operation that cuts the excess material from a finished or nearly finished part from the blank. The leftover metal can either be sold or recycled.

Steps to Achieve High-Quality Parts through Metal Stamping

Metal stamping is a complex process. Other than the cutting and forming operations involved in sheet metal stamping, you need to perform multiple other steps to get a high-quality finished part.

Planning and Design: The first step for creating a high-quality finished part is planning and designing a custom tooling to meet the specific needs. A prototype is created to be sure about the specifications planned for the actual part.

Preparation of Dies: A die is a specially shaped tool that is used to cut or shape material by using a press. It is customized to the items that are planned to be created using the die.

Cutting and Forming: A series of cutting and forming processes are performed to give the desired shape to the metal piece.

Quality Check: After the final part is received, it goes through a rigorous quality check to keep up with the industry standards.

Pros & Cons of Metal Stamping

Metal stamping for part creation has multiple benefits over common fabrication processes.

Some advantages of the metal stamping process include:

  • Produce a large volume of parts with quick turn-around times.
  • The cost of metal stamping dies is cheaper than the regular ones.
  • Secondary cost like the cost of cleaning and plating is significantly low in stamping compared to other metal fabrication processes.
  • Stamping uses high-end automation programs to offer greater accuracy and better production.
  • An operator without a high level of skills can operate it easily.
  • The leftover scrap metal can be recycled for future use.

However, the metal stamping process has a couple of disadvantages as well, like:

  • The cost of the presses is higher.
  • In case the design needs to be altered, it is expensive and complicated to change the dies during the production process.

Industries that Use Metal Stamping

From electronics and home appliances to agriculture and aerospace, today metal stamping is used to produce desired finished parts in various industries across the world. A whopping $42.5B industry, metal stamping produces highly specialized machinery, industrial equipment, and regular consumer products.

Some of the industries where metal stamping is highly used are:

Agriculture: The agriculture industry needs components that are economical, strong and are of the highest quality. Metal stamping is used to produce stamped parts, deep dawn shells and many other agricultural equipments.

Home Appliances: Metal stamping is used extensively to produce home appliances. Fan blades, shields, motors, washers, dryers, kitchen appliances are some examples of sheet metal stamping in this industry.

Electronics: Some of the component parts produced for the electronics industry are connectors, fittings, sensors, shells, couplings and more.

Oil and Gas: In the oil and gas industry, metal stamping is used to produce parts like washers, handles, brackets, etc.

Automotive: In the automotive industry, metal stamping is used to produce a wide variety of products like fuse boxes, bus bars, shields, brackets, and many others.

Aerospace: Precision metal stamping is used in the aerospace industry to create engine parts and aircraft components like connectors, fasteners, bus bars, terminals and more.

How to Choose the Right Metal Stamping Supplier?

Choosing the right metal stamping manufacturer is very important for receiving the best quality finished parts. The metal stamping process is complex in nature and only those with a high degree of knowledge about which metal to use and the right cutting and forming process can deliver the best design with high quality.

Metal Stamping Manufacturing

Try to get the answers to these questions and you will find out whether it is the right metal stamping vendor for your business.

Do They Invest in Technology?

A good metal stamping supplier must invest in the latest technologies to stay up to date with the industry standards. Tooling design is very important in manufacturing. Check out if the vendor uses the latest CAD/CAM software for die tooling design and have best in class machines use for die manufacturing along with experienced engineers.

Do They Offer All-Round Services?

You may need a variety of services from time to time. So, search for a provider who can offer all-round services like tooling, molding, assembly, packaging so that you can get everything under one roof.

Do They Maintain Quality Standards?

Quality is what sets your supplier apart from the competition. Ask and check for the quality standard certification of your supplier. Whether it is ISO, IATF or other quality standards, they need to be certified in one of them. This also proves their attitude towards delivering part products that are of the highest quality.

Your Ideal Partner in Metal Stamping

Eigen is one of the most reputed names in the metal stamping industry. We have years of experience and expertise to offer superior quality products with quick turn-around time. We are your all-round partner to help you with all your metal stamping needs.

To find out more about the metal stamping process, how it works, and how we can help you with our business, give us a call on (+91) 80 61111300 or write us to info@eigenengineering.com.

Eigen’s 20 year of expertise in:

  • Custom Engineered High Tolerance Components
  • Complex and Critical Parts
  • Turnkey Packages
  • Assembly & Sub-Assembly

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Why Eigen

Why EIGEN?

Backed by decades of expertise in design, development, manufacturing and supply of progressive metal stamping tools and components.

Location

Located in the technology capital of India, we have quick access to ports, easy availability of established vendors and excellent tool making expertise.

Reliability

Eigen is a supplier for Customers in Europe, the USA in the aerospace, locomotive and electronics segment with proven track record of product quality, customer service and delivery performance.

Professional expertise

Eigen has the proven track record of design, development and manufacture of progressive press tools up to 45 stages with complex profiles.

Testimonials

what our partners have to say about us

Backed by decades of expertise in design, development, manufacturing and supply of progressive metal stamping tools and components.

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“Excellent tool room facilities, very satisfied customers.”

- Anil.K.Srivastava, DGM, Connectwell Industries (P) Ltd.

“The parts I saw adds to my conviction that you are a quality Operation. This lends credibility to the nation and you will be successful in making our parts.”

- Leonard Challenger, Saft, USA

“Great systems and organisation. You are our potential supplier for stamped parts.”

- Umesh Kini, Global sourcing, Tyco Health care