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Progressive Tooling

Progressive Tooling is the widely used by Eigen to produce a wide range of parts and components. It is a metal stamping operation in which several procedures are performed in a progressive press. The process involves multiple stages in a fixed order to transform a metal strip into desired metal parts. The material is automatically fed from a spool into the press and continues from one stamping position to the next with each press stroke. Each station along the path carries out a certain operation simultaneously as the die descends until the part is complete in progressive tooling. Different steps are integrated within a single die, which allows for progressive tooling solutions in a quick, efficient and cost-effective manner.

What is progressive tooling?

Progressive tooling is an efficient alternative to transfer presses, allowing the implementation of several stages in a single move. The objective of designing it is to process strip material, which gets pushed and guided ahead with every stroke.

Progressive tooling systems are part of an automatic stamping press or progressive die which is a tool that carries out multiple operations in a punch press. The end product gets processed successively at consecutive processing stations. It gets separated from the band using specific operations performed only at the final station. This final product then falls off the press from an opening in the press into the container provided to catch the final components. Moreover, every production cycle generates scrap metal, which containers placed near the conveyor belts collect as it free falls off the stations.

Typical applications for progressive tooling systems are in the electronics, household appliance and automobile manufacturing companies. These tools are instrumental in reducing production costs significantly.

How Does Progressive Die Work?

The progressive stamping process takes place in a progressive die, a tool that performs multiple operations in one movement instead of multiple. A progressive stamping die is kept in the die stamping press. With the press moving up, the die moves together with it, allowing feeding of the material. As the press comes down, the die is closed, completing the stamping process. With every press stroke, one whole part gets removed from the press. There is also scrap metal produced, collected in a container with the help of conveyor technology.

The progressive stamping process can be carried out on a transfer press too. These presses transfer product parts using mechanical arms from station to station. But when you are mass producing components, you should always choose progressive die stamping.

Our progressive press tools:

An automatic stamping press uses progressive stamping tools. These tools cut down manual functionality and human error by automating the production journey significantly. Progressive tools also play a significant part in cutting down production and labour costs. The most common applications for progressive tools are within the automobile industry, household appliance manufacturing and electronic device industry.

Eigen offers highly recommended progressive tools for twice the production output, especially for an intricate component design that needs varying surface thickness in the final product.

Eigen Delivers Value in Progressive Tooling

We have a top of the line progressive tooling die and tool shop that enables us to excel at progressive die stamping. We are able to customize progressive die designs as per customer specifications as we have the ability to manufacture in-house. We have successfully developed complex press tool profiles with 45 stages, and have the capability to design, develop and manufacture profiles of even higher complexity.

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Progressive dies are used for high-volume manufacturing and are fashioned to operate at high speeds. Eigen produces high-quality, reliable and cost-effective progressive dies. We have the proficiency and technological know how to fabricate, quality test and produce robust progressive tools that tackle a broad spectrum of production challenges. The key to our success is our superb craftsmanship. We routinely work with aerospace, electrical and electronic industries, in addition to industrial engineering, automotive and ancillary units as well as consumer durable industries. Eigen recommends progressive tool stamping for tooling with insert construction to facilitate on-the-double component replacement imperative in high-wear manufacturing processes as well as for intricate designs that require coiling and varying material thicknesses in the final outcome.

Advantages of Eigen’s Progressive Tooling Services

One of the advantages of doing business with Eigen is that it allows us to meet customer demands quickly, whether for high or low volume parts. We always ensure perfection in our products, to match customers’ expectations exactly and on the deadline. The other reasons why Eigen is the obvious choice for progressive tooling and die design solutions are:

  • Speed – Eigen provides the lowest cycle times per part for high volumes.
  • Less Scrap Material – As the majority of the metal is used up in the process of progressive stamping, encompassing punching, coining, bending and several other ways of modifying metal to produce the desired end part shape, very less scrap are produced. Progressive Die Metal Stamping provides the most cost-effective material option for manufacturing parts.
  • Quicker Setup – Progressive stamping utilizes lesser time than the traditional machining setup. This will result in a more cost-effective piece part.
  • Longer Runs – Longer runs between metal changes and tooling adjustments allow parts to be produced in a much shorter time.
  • Lower Cost per Part – All the above-mentioned factors such as high speed, quick setup, longer runs, less scrap material, and so on, contribute to an overall reduced cost for you. Progressive die stamping enables the production of robust parts in a cost-effective and speedy manner.
  • Long Lasting Designs – Our tool room uses the best technology to ensure that each component produced lasts a lifetime.
  • International Standards – The press tools and specialized multi-cavity molds we manufacture are compliant with the highest industry and global standards.
  • Quick Modifications – As our designing and manufacturing is done in-house, we are capable of accommodating engineering changes as and when they happen, and incorporate the modifications quickly.
  • State-of-the-art Equipment – We use cutting-edge Wire EDM technology to cut your parts accurately and economically.

Industry we serve

Aerospace: Aerospace uses components that have perfect precision and tight tolerance. Eigen specialises in exceeding customer expectations no matter how complex the product design is or the type of customization it requires.

Electricals and Electronics: Eigen is a trusted global electronics component supplier, offering a wide range of parts and services for manufacturers and suppliers.

Automotive: Every automobile manufacturer requires a wide range of components. Eigen specialises in services like prototyping, stampings and large and medium production runs.

Industrial Equipment: Eigen supplies components created through precision stamping for power generation, agriculture, construction and other industrial engineering markets.

Consumer Durables: We understand that consumer durables must have the shortest time to market to maintain their competitive edge. Eigen’s industry experience and expertise enable us to offer product designers a range of components that help them deliver reliable and competitive products.

Frequently Asked Questions

Progressive die stamping refers to a process of metalwork that manufacturers use to create components utilized in a wide range of industries, such as electronics, appliances, automobiles, and aerospace, among others. A raw metal strip is put through a stamping press to form a finished part through progressive tooling. This part is assembled with other components to form a finished product.

A compound die is a mold structure processed in one stroke, using mechanisms like punching, stamping or bending in a single stroke. These are simpler components and are cost effective. While progressive die is a sequence die which uses multiple processes such as cutting, bending, forming and stretching. These require significant investment.

Sheet metal pressing and stamping are more cost-efficient than other processes because they reduce the per-unit costs and labour charges.

Transfer and progressive die stamping are different processes used for stamping metal components with a wide range of applications. Manufacturers choose a method based on the volume of components to be manufactured, the product’s nature, and the rate at which they require the components.

Eigen’s 20 years 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