One of the best manufacturing solutions for producing lightweight precision metal products is metal stamping. Today, we’ll take a look at some of the many applications of lightweight parts and how metal stamping manufacturers craft them with quality and performance in mind.

Applications of Lightweight Precision Metal Products

Automotive

In the automotive industry, the pursuit of fuel efficiency and performance has been one of the main driving factors for the adoption of more lightweight precision metal products. Lightweight metal stamped parts in the automotive sector include body panels, chassis components, suspension parts, engine and powertrain components, among others.

Depending on the application, lightweight components may need to provide a range of characteristics. For instance, lightweight body panels should both contribute to the reduced weight of the vehicle and enhance the crashworthiness of the car. On the other hand, lightweight chassis components need to exhibit stiffness and rigidity to provide structural support.

Aerospace

In the aerospace industry, lightweight precision metal products are integral to everything from aircraft structures and engine components to landing gear and avionics enclosures. By using materials such as aluminum, which has a high strength-to-weight ratio, lightweight metal components enable reduced fuel consumption and an increased payload capacity.

But beyond that, lightweight metal parts in aerospace applications are also manufactured to withstand harsh conditions (particularly in engines), maximize strength in landing gear, and provide superior protection for sensitive electronics.

Electronics

Lightweight precision metal components are widely used in the electronics industry. They are invaluable to the fabrication of electronic enclosures, connectors, and contacts. In each case, the lightweight metal part delivers more than weight reduction. Excellent protection against impacts and the elements are essential for enclosures designed to protect items like smartphones, tablets, and laptops.

Meanwhile, in the case of connectors and contacts, lightweight metal parts must be designed to maximize space usage within electronics while also facilitating the reliable flow of electricity throughout the product.

Medical

Lightweight precision metal products in the medical industry are often found in things like implantable devices and diagnostics equipment. Lightweight metal stamped parts are especially important for implantable devices like stents, orthopedic implants, and surgical instruments where biocompatibility and durability are essential.

In diagnostics equipment, stamped parts are utilized in X-ray machines, MRI scanners, and surgical instruments to optimize portability and ease of use for healthcare workers and patients alike.

Consumer Goods

The consumer goods industry utilizes lightweight stamped metal parts in the manufacturing of household appliances and sporting goods. Appliances like refrigerators, dishwashers, and microwaves require parts that support both a lightweight construction and longevity for a better consumer experience.

Similarly, sporting goods also incorporate lightweight stamped metal parts in products like bicycles, golf clubs, and pads and helmets for durability and ease of use that enhances performance and user experience.

Telecom

Finally, lightweight precision metal products are highly important in the telecom industry. Lightweight components are frequently used in the production of networking equipment like routers, switches, and antennas to provide structural support and heat dissipation properties.

In mobile devices, stamped parts are utilized in the production of components to create a lightweight, compact design while also providing robustness and reliability to keep up with everyday use.

How Metal Stamping Manufacturers Achieve Lightweight Precision Metal Products

In order to craft these lightweight precision metal products, metal stampers take a number of factors into consideration, including:

• Material Selection—Material selection is absolutely critical for lightweight parts and often depends on the specific application in which they will be used. For instance, the requirements for lightweight aerospace engine components will vary drastically from those of medical implants. It’s important to work with a metal stamper who understands the nuances of your application.

• Material Thickness Optimization—To determine material thickness, manufacturers will analyze the structural requirements and mechanical loads that the lightweight component will experience during operation. From there, they will optimize material thickness to achieve the necessary strength and stiffness by selecting the thinnest feasible material gauge that still meets strength requirements.

• Design for Manufacturability (DFM)—Metal stampers collaborate closely with engineers to ensure that components are designed with DFM in mind. They do this by assessing factors like draft angles, fillet radii, and material flow to minimize the risk of defects and ensure part quality.

• Hollow Sections and Cutouts—Metal stampers can leverage hollow sections and cutouts to further reduce the lightweight components without sacrificing functionality. By utilizing advanced forming techniques like deep drawing and piercing, metal stampers can create intricate shapes while maintaining structural integrity.

• Surface Treatments—Metal stampers apply surface treatments to improve performance and durability. Such treatments include anodizing, plating, coating, and painting, which can enhance corrosion resistance, wear resistance, and aesthetic appearance while maintaining low weight.

Get Lightweight Precision Metal Products with Die-Matic

At Die-Matic, we provide turnkey metal stamping solutions for customers in a wide range of industries. Our capabilities include metal stamping, tool & die, assembly, prototyping, and value-added offerings for end-to-end manufacturing services. Whether you need custom lightweight precision metal products, or something more standard, our team of seasoned professionals is here to deliver.

Connect with us today to get started with a comprehensive free quote.

The post How Metal Stamping Manufacturers Produce Lightweight Precision Metal Products appeared first on Die-Matic Corporation.

Long-lasting, high-performance metal stampings make up a good portion of these parts, and they’re essential for supporting agricultural operations every day. Let’s take a look at how metal stamping manufacturers go about ensuring quality and longevity in agricultural machinery parts.

The Role of Metal Stampings in Agricultural Machinery Parts

Metal stampings comprise several vital agricultural machinery parts. Brackets, mounting plates, housings, and enclosures, and so much more are all parts commonly manufactured via the metal stamping process. In order to ensure performance and durability, metal stampers generally turn to materials like steel, stainless steel, and aluminum. By the end of the process, metal stampers aim to produce agricultural machinery components that are long-lasting, high-performance, and cost-efficient.

How Metal Stamping Manufacturers Deliver Long-Lasting Agricultural Machinery Parts

In order to deliver optimized agricultural machinery parts that facilitate smooth and efficient farming operations, metal stampers employ a number of key strategies during the manufacturing process. These include, but are not limited to:

Engineering design—Design considerations like material thickness, geometry, and reinforcements can all be tailored to enhance strength and improve the longevity of metal stamped parts in agricultural applications.

Precision manufacturing—With precision tooling and machinery that can produce parts with tight tolerances, manufacturers can help ensure that parts fit together accurately during assembly, which minimizes wear and tear due to misalignment or excessive friction.

Surface treatments—Metal stampers can add surface treatments such as plating, coating, or painting to enhance the resistance of metal parts to corrosion, abrasion, and other forms of degradation.

Stamping techniques that enhance structural integrity—Through techniques like deep drawing, bending, and forming, these can create components with high structural integrity and resistance to failure under load.

Quality control—By incorporating rigorous quality control measures throughout the process, metal stampers help ensure that all agricultural equipment parts meet specified standards and requirements.

The Advantages of Metal Stampings in Agricultural Machinery

So other than long-lasting parts that maintain high performance levels over the long-term, what are some other advantages that metal stampings bring to agricultural machinery?

Weight reduction is one of the biggest advantages. In many agricultural operations, there is a growing emphasis on lightweight designs that consume less fuel and improve maneuverability. Lighter weight agricultural equipment parts also means less stress is being placed on the machine as a whole, allowing it to function at optimal levels for longer periods of time without the need for repairs or maintenance.

Metal stamping also allows for the production of parts that have been engineered to withstand harsh operating conditions, heavy loads, vibration, and exposure to contaminants. It’s also relatively easy to customize the shape and dimensions of individual parts to accommodate unique or changing needs. Both of these contribute to a greater level of flexibility and enhanced performance of the end product.

Ensure the Performance of your Agricultural Machinery with Stamped Parts from Die-Matic

For more than 60 years, Die-Matic has provided comprehensive metal stamping solutions for customers in a wide range of industries, including the agricultural industry. With our extensive capabilities in metal stamping, our focus on excellent customer service, and our value-added and post-production offerings, we deliver turnkey solutions for both standard and custom components.

Are you ready to partner with a manufacturer that has your project covered from end-to-end? Get in touch today to get started.

The post How Metal Stamping Manufacturers Deliver Long-Performing Agricultural Machinery Parts appeared first on Die-Matic Corporation.

Miniaturization and High-Performance in Precision Metal Products

The miniaturization of precision metal products has played an important role shaping innovation across various sectors by enabling the creation of smaller and more intricate components. One of the most impacted industries has been the medical industry. Precision metal products such as those used in pacemakers, neurostimulators, and drug delivery devices have become smaller and more sophisticated. This allows for less invasive implantation procedures, reducing patient discomfort and recovery times.

Similarly, in the electronics world, mobile devices and wearables have seen great advancements thanks to miniaturization. Precision metal components contribute to small, lighter weight, and more user friendly devices that are more portable and convenient. The semiconductor industry also relies on miniaturization for the production of microchips and integrated circuits, which leads to higher processing speeds, increased memory capacity, and better energy efficiency.

Enhanced Durability of Lightweight Parts

In industries like automotive and aerospace, precision metal products need to support the functionality of the entire product, whether that is a UAV, a sports car, or a passenger airliner. But, metal parts also need to be durable, resistant to harsh environmental conditions, and lightweight. Lightweight parts for these applications are integral to enhancing fuel efficiency and reducing wear on the rest of the machinery and equipment. Metal manufacturers have been able to achieve this partly through high-strength alloys and composite materials.

Increased Efficiency and Energy Savings From Precision Metal Products

Precision metal products have enabled increased efficiency and energy savings in a wide range of industries, but in the energy and transportation sectors especially. Precision metal gears and transmission components, for example, facilitate smooth power transmission and meticulous control of speed and torque in transportation applications. They also lead to improved fuel efficiency, better performance, and, in aerospace, improved flight longevity.

In the power generation sector, precision metal components are important in gas and steam turbines. Precision blades and components are able to optimize energy conversion by efficiently harnessing the energy from fluid flow. The same can be said of generator systems, where metal parts play a key role in converting mechanical energy into electrical. In both respects, precision metal products are essential for minimizing energy loss and improving overall system performance.

Precision Metal Parts Deliver Optimized Thermal Properties

Finally, precision metal components that have been designed for optimized thermal properties are vital to heat management in a variety of applications. For instance, precision metal heat sinks are designed to dissipate heat generated by electronic components, such as processors, transistors, and power modules. These prevent electronic components from reaching critical temperatures, allowing for more reliable and consistent performance.

Brackets and frames that have optimized thermal properties are also widely used in the solar panel industry. With efficient heat dissipation and minimized temperature buildup, solar panels have been made more efficient in recent years than they have been historically.

Choose Die-Matic for Your Precision Metal Products

At Die-Matic, we’re a full-service metal manufacturer that has been supporting our customers with precision metal products since 1958. We have extensive capabilities in metal stamping, and our Ohio-based facilities are equipped with the latest in advanced manufacturing technology. With a team that prioritizes transparency and next-level customer service, we have the expertise and the equipment to deliver exactly what you need.

Connect with us today to get started.

The post How Precision Metal Products are Shaping the Future of Innovation appeared first on Die-Matic Corporation.

Metal stamping and assembly manufacturing partners are an important part of maintaining a healthy supply chain. When you choose a single partner that offers both services, it can result in significant reductions to your lead times and time-to-market, as well as cost savings.

What is a Single Source Metal Stamping and Assembly Partner?

A single source metal stamping and assembly partner, as you might imagine, is one that provides a comprehensive range of services within metal manufacturing. They offer integrated solutions that simplify communication, minimize the risks of misunderstandings, and eliminate the need for dealing with multiple vendors.

Choosing a single source partner often results in shorter lead-times, cost savings, and better quality control. And, because single source metal stamping and assembly partners are capable of handling various stages of production—from design and prototyping to assembly and packaging—they have a built-in ability to scale with your needs, no matter how quickly or frequently they may change.

Next, let’s take a closer look at exactly how single source metal stamping and assembly partners can positively affect your supply chain.

How Single Source Metal Stamping and Assembly Partners Impact Your Supply Chain

Supply Chain Consolidation

By consolidating various stages of the production process with a single source partner, things like raw material sourcing, production, and assembly can all be streamlined. This, in turn, can lead to simplified procurement, making your supply chain more reliable and consistent. It can also significantly reduce the complexity of inventory management. Making changes to your orders, scaling production up or down, and putting in time-sensitive requests is much easier with a single source partner that can respond quickly and adapt every part of your production process to meet your current needs.

Streamlined Communication

With a single point of contact, you can reduce the likelihood of miscommunication, misunderstandings, or delays that can occur when dealing with multiple vendors. With clear communication channels that foster an efficient exchange of information, you can build a much stronger relationship with your metal parts supplier. In turn, this can lead to your single source manufacturer becoming a partner in the truest sense: one that can help you optimize your part designs and improve the overall quality of your products.

Reduced Lead Times

With all manufacturing processes under one roof, a single source partner can often offer shorter lead times. With less dependency on outside suppliers, the coordination between different stages of production is much smoother and quicker. With reduced lead times, your single source metal stamping and assembly partner can achieve faster production and delivery of finished goods. Shorter lead times also means more flexibility for your partner to respond to changes in the market.

Cost Efficiency

By consolidating your manufacturing processes into a single source partner, it eliminates the need to manage relationships with multiple partners, reducing administrative overheads. It can also lead to better economies of scale through bulk purchasing and integrated services.

Better Quality Control

With a single source metal stamping and assembly partner, it’s much easier to implement a unified quality control system throughout every stage of production. This helps ensure consistency and adherence to quality standards. It also reduces the risks of defects and reworks, helping to secure your supply chain against unplanned shortages or disruptions.

Enhanced Problem Resolution

Finally, choosing a single source partner facilitates more efficient problem resolution. When your manufacturing partner is more holistically involved in your entire production process, they’re better able to identify and resolve problems in a timely manner. It also empowers your manufacturing partner to be proactive. Manufacturers who are involved in every stage are more likely to be familiar with your needs, your industry, and any challenges that might be on the horizon.

Some Things to Consider

Consolidating your supply chain with a single source metal stamping and assembly partner comes with a range of benefits, but there are a few things to be aware of. For instance, while your supply chain is generally more secure with a single source partner, it also means that any disruption to your partner’s supply chain will impact yours as well. It’s important to have contingency plans and to choose a partner that prioritizes the reliability of their own supply chain.

You should also ensure that whatever partner you choose, they have the capacity and scalability to meet your demands now and in the future. A manufacturing partner that lacks this can become a major bottleneck for business growth. It can also present a slew of other problems if you end up having to move your processes to a new partner later on down the road.

Die-Matic Provides Innovative Solutions Throughout the Metal Manufacturing Process

Since 1958, Die-Matic has been providing manufacturing, prototyping, die & tool, and assembly services for customers in a wide range of industries. We are proud to be a single-source partner that can simplify your supply chain with our decades of expertise, our investments in the most advanced manufacturing technology, and our customer-oriented team of experts. Located in Brooklyn Heights, Ohio, we provide comprehensive metal manufacturing solutions for customers in Ohio and the surrounding states.

Connect with our team to get started on your next project today.

The post How Choosing a Single Partner for Metal Stamping and Assembly Can Simplify Your Supply Chain appeared first on Die-Matic Corporation.

Wielding 220 tons of force, this versatile press gives us added flexibility with part stamping. A traditional press moves up and down (stroke) in one set way with the same force and speed each time. This new press has a working stroke close to ten inches, but it is infinitely adjustable down to one inch and has adjustable cycle speed – referred to as a pendulum motion. The force and speed can be adjusted throughout each stroke, even stopping briefly, allowing us more control for creating complex shapes. This is customizable on a job-by-job basis, and once optimized, it is stored as a recipe to ensure repeatability for all future runs. Plus, it wastes less energy, making it a more environmentally friendly machine.

The new press allows us flexibility to perform complex projects with ease. For example, some challenging parts have issues with spring back (when the material tries to return to its original position after being bent). With this press, we can program a double or triple hit near the bottom of the press stroke to overcome spring back, which, if not mitigated, could affect the part’s dimensional accuracy. Another use is for parts requiring deep coin displacements. They may be struck multiple times to ease the metal into an accurate final shape and size with no deformations or deviations that may otherwise occur. Additionally, we can also explore other opportunities for the press, including briefly halting a cycle for in-die assembly and inspections, opening more possibilities and greater efficiency in our processes.

The  flexibility, adaptability, and best-of-all-worlds in press-working brings many benefits that ultimately benefit our customers:

• It makes better-quality parts more efficient.
• It expands possibilities for part designs.
• It saves energy by using only the needed force and speed.

Partner With a Company That’s Investing in Your Future

To provide our customers with the best experience, we know we must invest to advance our processes. By purchasing this new press, we are demonstrating our desire to help our customers remain competitive. With our commitment to quality, dependability, and customer service, we can provide you with innovative manufacturing solutions and high-quality parts. Contact us to learn more.

The post New Press Brings Expanded Capabilities and Greater Efficiency For Stamping for High-Quality Parts appeared first on Die-Matic Corporation.

Expertise and Experience

Precision metal stamping is a specialized manufacturing process that requires a deep understanding of tooling, materials, and precision engineering. A more experienced metal manufacturer is more likely to have encountered and overcome various challenges in the past, leading to a smoother and more efficient production process. This, in turn, provides a level of expertise that allows for better problem solving, design optimization, and overall quality assurance.

Beyond that, you’ll want to look for a partner with a proven track record and experience in your industry. Different industries have different standards and requirements, and a metal stamping partner with experience in your area is more likely to understand the specific demands, regulations, and quality standards that apply.

Technology and Equipment

Technology has always played a prevalent role in precision metal stamping, but in recent years that role has grown and evolved. Automation, AI, advanced machinery, and sophisticated quality control systems all contribute to a metal stamping process that is more efficient. As a result, a metal-stamping partner with up-to-date technology and equipment is better positioned to offer advanced solutions that help you maintain a competitive edge.

On top of that, with a metal stamping manufacturer that consistently invests in new technologies, you can rest assured that their commitment to staying at the forefront of industry advancements is in line with your own.

Reliable Access to Materials

A metal stamper’s ability to source materials reliably is crucial for the success of the manufacturing process. Different projects often require specific materials with distinct properties. When your partner has established relationships with reputable suppliers, materials are more likely to be readily available, reducing the risk of production delays.

When your precision metal stamping partner has a more secure supply chain, it also means they’re better equipped to handle unexpected challenges so you can keep your production timelines on track.

The Right Capabilities

Finally, you’ll want to choose a precision metal stamping partner with the right capabilities for your needs. Whether it’s adapting designs, altering dimensions, or incorporating special features, your metal stamping partner should be able to customize their services in order to offer you tailored solutions.

Beyond the stamping process itself, a partner that offers value added and post-production services adds a layer of benefits. This might include assembly, finishing, coating, and packaging. These kinds of services can help streamline the production-to-assembly process and reduce your logistical burden.

Experience the Die-Matic Standard of Precision Metal Stamping

At Die-Matic, we’re more than just a parts supplier. We’re committed to providing solutions for each of our customers. Since 1958, we have delivered metal stamping and value added services to meet your metal components needs. With our commitment to quality, value, reliability, and proficiency, we are dedicated to solving problems that our customers may have experienced with previous partners.Are you ready to get started? Connect with our team of experts today.

The post What to Look for in a Precision Metal Stamping Manufacturer appeared first on Die-Matic Corporation.

Many of these changes are being driven by high-demand industries, such as alternative energy, and it’s always helpful to look ahead at the areas where shifts in demand and priorities could impact the way metal stampers provide services. With that in mind, here are the top trends expected to impact the metal stamping market in 2024.

A Focus on Alternative Energy

The alternative energy sector is one of the fastest growing markets out there. In fact, it’s expected to grow by an impressive 17.4% between 2024 and 2030. Thanks, in part, to government incentives and regulations, more and more companies are looking for ways to reduce emissions, minimize energy consumption, and improve their eco-friendly practices overall. This has led to many businesses and organizations turning to alternative sources like wind and solar to fulfill at least a portion of their energy needs.

As a result, metal stampers that produce brackets and bi-polar plates for alternative applications may soon see an increase in demand compared to previous years.

An Emphasis on Lightweight Parts

Another area that is expected to impact the metal stamping market is the continued emphasis on lightweight parts. Lightweight parts are becoming more and more vital to industries like automotive and aerospace for the purposes of improving fuel efficiency and meeting federal requirements on emissions. Metal stampers have a vital role to play in this by providing lightweight parts that meet performance standards.

Lightweight metal parts also play a crucial role in consumer electronics, making them more portable and user-friendly. For the metal stamping market, this likely means an increased focus on working with lightweight materials and using processes that allow for the creation of intricate components.

Continued Focus on Automation and Technology

One of the biggest advancements in the metal stamping market has come from the integration of automation and technology into manufacturing processes. In-cell robotics, palletizers, sensors, SPC systems, and quick die change (QDC) systems are only a few of the ways that technology has become central to metal manufacturing.

These systems enable manufacturers to speed up production while maintaining the enhanced efficiency many customers require. They also free up workers for more skilled tasks and can significantly reduce waste in some cases. With the rise of functional AI and the advantages that automation offers, it’s likely that this will continue to shape the metal stamping market in significant ways moving forward.

Tackle Future Challenges with Die-Matic

At Die-Matic, we’ve been providing metal stamping and value added services since 1958. With our focus on excellent customer service and our investments in the latest technology, we pride ourselves on being a versatile manufacturer for a wide range of industries. With our metal stamping, welding, and prototyping capabilities, we aim to be your go-to for all your precision metal components.

Connect with our team today to get started.

The post The Future of Metal Stamping: Predictions and Projections for 2024 appeared first on Die-Matic Corporation.

Today, it’s more important than ever for businesses to have access to precision metal stampings at prices they can afford. In order to do this, finding a manufacturing partner who knows how to balance value with affordability is essential. But how exactly can manufacturers help you save money on your metal components? Let’s find out.

The Value of Precision Metal Stampings

First, it’s good to remember why precision metal parts are so essential. Precision metal stampings play a vital role in critical applications across multiple industries and, when produced by experts, can also help improve overall ROI.

For instance, in the electronics industry, precision metal stampings serve as connectors, lead frames, and shielding components in products like smartphones, laptops, and tablets. Using stamped metal parts ensures tight tolerances, reliable connectivity, and more cost-effective mass production.

Similarly, in the automotive industry, safety and reliability are non-negotiable. Precision metal parts can contribute to the longevity and performance of automotive components, leading to better products, a reputation for quality, and much better customer satisfaction.

So when it comes to saving money on precision metal parts, it’s equally important to maintain a high level of quality and performance. The right manufacturing partner can help you do just that in a few key ways.

Design Optimization for Cost Savings

One of the most important factors to consider when trying to find cost savings for precision stamped metal parts is the design of the part itself. In this, the knowledge of your manufacturing partner is invaluable.

One of the most effective ways to find cost savings is to prioritize design for manufacturability, or DFM. DFM is the practice of creating a part design that is easy and efficient to produce. One way to do this is to simplify the part geometries as much as possible. Symmetrical designs are often more cost-effective to manufacture, and avoiding unnecessary shapes and features can also reduce production time and tooling costs.

Manufacturing partners can even sometimes take that one step further by standardizing parts that are used across different productions and assemblies. This can lead to economies of scale and reduced production costs.

Another area of focus for many manufacturers is the process of prototyping and testing. Investing in early prototyping in the design phase helps identify potential issues before mass production. This enables manufacturers to avoid costly redesigns and tooling adjustments later in the process.

Saving on Precision Stamped Metal Parts with Material Efficiency

In order to keep costs manageable, the right manufacturing partner can also help enhance material efficiency. This starts with material selection. Choosing a material that meets the performance requirements of the part is critical, but it’s also important for cost to select materials that are readily available and relatively easy to get.

There are also a number of ways that manufacturers can reduce material waste throughout production (and thereby reduce overall costs). One is taking advantage of piercing operations. On a more advanced level, experienced manufacturers are capable of strategically designing tools to minimize scrap and optimize the cutting and forming processes.

When viable, choosing a thinner gauge or reducing material thickness is also an effective way to save money without sacrificing quality. Your manufacturing partner should be able to help you make those decisions.

Tooling and Die Efficiency

Let’s take a closer look now at how manufacturers can optimize die efficiency for more cost-effective production.

First, investing in high-quality tool design can help ensure accurate and consistent production, minimizing both errors and the need for rework. More durable tools also require less maintenance and can help reduce replacement costs.

On that note, however, regularly scheduled maintenance can help prevent unexpected breakdowns, extend the life of dies and tools, and minimize downtime.

Manufacturers can also leverage the power of technology and data to optimize the die. CAD, simulation software, sensor technologies, and monitoring systems that track the performance of the die all feed into the enhancement of precision, reduce errors, and enable manufacturers to make more informed decisions.

Optimizing the Production Process for Precision Stamped Metal Parts

Other areas of the production and post-production processes can also be optimized for more cost-effective precision stamped metal parts. Some examples include:

• Automation of repetitive tasks, for example, greatly increases efficiency and reduces labor costs.

• Lean manufacturing aims to minimize waste, provide efficient inventory management through JIT-shipping, and adapt quickly to changes in demand or production requirements.

• Quality control and inspection help monitor and control the production process to ensure consistency and quality.

• Value engineering helps identify opportunities for further cost reduction without sacrificing performance.

• Supplier relationships that are nurtured and well-developed can foster higher levels of collaboration and mutual understanding.

Die-Matic is a Trusted Partner for Precision Stamped Metal Parts

At Die-Matic, we’re a manufacturer that delivers metal stampings and value-added assemblies. We’ve been in business since 1958 and in that time we’ve been able to refine our processes so we can provide you with cost-effective manufacturing solutions that don’t compromise on quality. With our team of highly skilled professionals and the latest in advanced manufacturing technology, your production is in the best hands when you decide to partner with us.

Do you have a project coming up? Connect with us today to get started.

The post Maximizing ROI: Cost-Saving Strategies for Precision Stamped Metal Parts appeared first on Die-Matic Corporation.

Because metal stamping can be advantageous for so many different applications, it’s useful to have a deeper understanding of what the process involves and how manufacturers achieve precision and quality through metal stamping.

Preparing for Metal Stamped Parts

Before producing metal stamping parts, manufacturers and their clients must go through a series of important steps to ensure the final product meets expectations.

The first step is often the design phase. During the design phase, engineers and product designers work together to make sure that the part meets the desired functionality, cost, and quality requirements. It can be an extensive process, but it often involves material selection, obtaining cross-functional team input, defining tolerances and specifications, prototyping and testing, and maintaining documentation.

Preparing for the production of metal stamping parts also involves careful consideration of tooling. Tooling is pivotal to an efficient, precise, and successful manufacturing process. Choosing the right tools involves selecting the appropriate dies for the project and collaborating with design engineers to prove out the intended process in the prototype phase.

Manufacturers are also essential for ensuring the safety of metal stamped parts with tools designed to remove burrs and smooth out sharp edges.

How Metal Stamped Parts are Produced

A progressive die is a sequence of stations that allows for a specific design or part to be produced after a coil has passed through each station. Ergo, the name “progressive” die. In essence, a coil (or strip) of metal is fed through station #1, then stamped before being moved to station #2 and 3 and so on.

While the specifics of the stamping process can and often do vary according to project needs, a basic sequence might look something like the following.

Step #1: Piercing

Piercing involves creating pilot holes or openings in the metal coil. These holes are what keep the coil in place as it is fed through all of the subsequent stations. Without these pilot holes, the metal coil can slip during the rest of the process. Because of that, piercing is essential for producing parts that are accurate and uniform. It also contributes to the repeatability of the stamping process.

Step #2: Trimming

This part of the process can actually involve two or three different stations. Essentially, manufacturers use this phase to trim the outside profile of a part without detaching it from the carrier strip. This allows the part to be movded from one station to another.

Step #3: Forming

The next stations involve forming. When producing metal stamping parts, the forming process is when the shape of the metal component is manipulated to achieve specific contours, bends, and features.

The forming step involves using a forming press or brake press and specialized tools. Common forming techniques include bending, embossing, and coining.

Step #4: Another Round of Trimming For Metal Stamped Parts

Again, this stage may involve two or three stations and allows for the addition any holes, slots, or shapes that may be needed to pierce the parts. This round of trimming comes right after forming because it enhances the accurate placement of those particular features.

Step #5: Cut-Off and Idle

The last series of stations often involve an idle station and the cut-off station. In the cut-off station, the final part is separated from the metal strip. From there, it goes onto a conveyor to exit the tool and press.

Idle stations are on standby in case there are future engineering changes that impact the design of the part, or in case the original die design needs to be modified in the event that it cannot make the part as intended. Think of these stations as spare tires: they are there if needed.

Optional Value-Added Items

Finally, there are some optional value-added items that can be included in the tool & die, including:

• In-die cinching
• In-die staking
• In-die “nut” insertion
• In-die “stud” insertion
• In-die tapping

A collaborative metal manufacturing partner can help you decide whether these processes would be beneficial to your project.

Quality Control and Inspection

Quality control and inspection processes are often implemented throughout the process of metal stamping parts. The purpose is to identify and rectify defects, maintain consistency, and deliver high-quality products. In metal stamping, quality is heavily reliant on characteristics of the raw material such as hardness and thickness.

From there, a number of monitoring processes can be put into practice such as:

• Statistical process control
• Process capability analysis
• Visual inspection
• Dimensional inspection
• In-process inspection
• And final inspection

By implementing robust quality control measures, manufacturers can enhance product reliability, reduce defects, and maintain a high level of customer satisfaction.

Post-Stamping Processes

Production doesn’t end when the metal stamping process is complete. In order to produce truly high-quality metal stamped parts, manufacturers rely on a selection of post-stamping processes to refine the products. These processes include:

• Cleaning and deburring — This involves cleaning the part of any residues, oils, or contaminants and removing sharp burrs to create smooth edges that are safe for handling.

• Surface finishing — Surface finishing enhances the appearance or metal parts and improves corrosion resistance. Common techniques include polishing, buffing, grinding, and shot blasting.

• Coating and plating — Coating and plating can provide additional protection from corrosion, improve conductivity, and enhance durability.

• Welding Assembly — The use of various welding techniques are used to join separate components together to form a unified structure.

Trust Die-Matic for Your Metal Stamped Parts

At Die-Matic, we provide a range of metal manufacturing services for a variety of industries. Our solutions include precision metal stamping, value-added assemblies, progressive tool and die, prototyping, and welding. With stamping presses that range from 30 to 1,000 tons, we’re equipped to handle your most demanding metal stamping projects.

With the latest in manufacturing technology and a team of highly skilled professionals, we’re committed to being your partners throughout the entirety of production and beyond.

Connect with our team today to get started.

The post From Design to Production: A Step-by-Step Guide to Metal Stamped Parts appeared first on Die-Matic Corporation.

Benefits of a Sheet Metal Prototype

Successful products often start with a prototype or several iterations of a prototype to ensure the design is right before it goes into production. While there is a cost associated with developing a prototype, the value is far greater for custom-stamped parts.

Minimize Issues

CAD designs don’t always translate perfectly into real-world designs. Prototyping allows you to minimize downstream issues in stamping and secondary operations and identify product flaws, such as mating parts that don’t fit. It will also allow you to ensure your design is compatible with the metal stamping process.

Prevent Financial Losses

Discovering a problem with your design is much more expensive once it is in full-scale production. Metal stamping is a subtractive manufacturing method, so material that has been removed can’t be put back in the same manner. Reworking the parts, which is costly in itself, is likely not possible, so you are left with scrap. If critical flaws are discovered after the product is in commercial field use, you may face a product recall or a lawsuit if the defective part leads to an injury. Verifying functionality and safety through prototype studies before large-scale production can reduce risk and prevent financial losses.

Optimize Your Design

Prototyping streamlines design optimization. This is particularly beneficial for complex designs. For instance, if through the DFM process, you feel merging two parts into one is feasible, a prototype enables you to confirm functionality by testing different design options. Another advantage of prototyping is the ability to assess various materials to determine the most suitable for your application. By evaluating your design early on through prototyping, you can pinpoint potential cost reductions in design, materials, and production.

Planning Your Design

Prototyping is a critical step in the initial stages of creating a stamped product. Before you begin your product design, be clear about your product’s use and purpose to reduce the number of prototype iterations required. Evaluate the fit, form, and function, and feasibility of the part.

• Form refers to the part’s shape, dimensions, metal thickness, tolerances, etc.
• Fit is the ability of the part to interface or interact with other components, including material compatibility. Do holes line up? Is there enough clearance for moving parts?
• Function is the action the part is expected to perform, which may require a certain strength, chemical resistance, durability, etc.
• Feasibility is how successfully and cost-effectively the stamped part can be made. An overly complex design may add additional costs to the project.

Working closely with your metal stamping partner will ensure that your prototype and resulting final product will meet your expectations. Using precision metal stamping design for manufacturing (DFM) practices will help uncover any constraints in the manufacturing process, and the part can be manufactured cost-effectively without impacting quality.

Why the Sheet Metal Prototype Manufacturer Matters

Getting from ideation to production is often not a linear path, and you will face unexpected obstacles, twists, and turns along the way. As mentioned, a prototype will help to smooth out that process, allowing you to test a product under real-world conditions. Many companies specialize in prototyping, but there are compelling reasons to allow your metal stamping partner to develop your prototype.

Consistency From Prototype to Production Part

By using a separate service, such as a prototype house or engineering firm, you risk having your project churned out without regard to manufacturability or assembly, resulting in lost opportunities for improvement. If the engineers are not working in a full-scale manufacturing environment, they will not be privy to the nuances of the equipment and critical lessons not taught in textbooks.

Continuity of technology and process from your prototype to production will ensure that the final prototype design can be manufactured and will function as your production product. This is further assured when DFM principles are applied in the design phase. A separate prototype firm will not be able to design with the stamping manufacturer’s equipment in mind, so changes may need to be made to go into production.

Time Savings

When your metal stamping partner develops your prototype, you eliminate the time required to hand off the product, and learning curves are eliminated. If your stamper gets the drawing for your part and they are not compatible with their stamping processes or they notice a design issue, you are back to the drawing board. Changes will need to be made to the design, and your prototype is no longer a valid representation of your production part. When they are both done by the same manufacturer, the part can go straight into production, allowing you time savings to get to market faster or provide timely service to your customers.

Cost Savings

A lack of continuity and speed can both drive costs higher. Opportunities for improvement in creating cost reductions can be lost. Costs go up if the product must be redesigned. Slower time to market can impact potential sales and market share or disadvantage customers. Administrative and logistic costs are also eliminated when a single manufacturer is used.

Streamlined Communication

Fewer points of contact minimize misunderstandings and errors. There can be many people involved in the process of manufacturing a part. Sales, engineers, scheduling, operations, and purchasing are a few that may be involved in getting your project off the ground. Dealing with contacts from two companies trying to coordinate efforts can leave a lot of room for miscommunication. And when two independent companies are involved, you risk finger-pointing when an issue arises. Working with a single partner for your sheet metal prototype and manufacturing minimizes this risk and allows you to build a meaningful relationship with them.

Die-Matic As Your Single Partner

We can take your product from prototyping through value-added assemblies all under one roof. You save time and money and avoid the hassles created by working with multiple vendors. Contact us today to get your prototype started!

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