Metal stamping is a cold-forming process that uses dies and presses to cut and form sheet metal or coil stock into various shapes. Custom metal parts stamping can be done with progressive, deep draw, or single-hit stamping.

Progressive stamping effectively converts coil stock into a finished product with minimal handling and consistent repeatability. The metal coil feeds from station to station in the die, progressively becoming the finished part.

Deep-drawn stamping is a process for forming sheet metal into cup-shaped components. The center of the sheet metal is pressed into a die opening using a punch to draw the metal into the desired shape. The forming is considered deep drawn when the depth exceeds the diameter.

Single hit stamping uses a single hit die that is moved from station to station. Compared to progressive stamping, which is automatic, single hit dies require more interaction with the die and press. These dies tend to be smaller and more affordable.

Exploring the Cost-Effectiveness of Custom Stamping Metal Parts

Metal stamping is a highly cost-effective process. As a cold-forming technique, it does not require any heat to shape the metal, making it more affordable. It involves less labor and time than forging or casting, resulting in lower production costs.

Metal stamping is an effective way to quickly produce copious quantities of identical parts. It can also create intricate designs with precise measurements, ensuring high-quality output without compromising production speed. Additionally, metal stamping utilizes dies, which minimizes setup time and costs compared to other manufacturing techniques, such as welding or machining. While there are costs associated with creating the tooling, tooling is built to last and be used repeatedly. For high-production stamping, the efficiency, speed, and quality can offset the cost. An experienced tool designer will be able to suggest changes that can reduce complexity and remove costs.

Precision And Accuracy That Can’t Be Beat

Metal stamping is a proven process for precision and accuracy. Precision refers to how close measured values are to each other – the consistency or repeatability of a process. Accuracy refers to how close a measured value is to an actual value. For example, the measurement on the part will match the measurement on the drawing. When we say something has high precision, it means that even the 500th part is just as accurate (good or bad) as the first. It is important to note that accuracy and precision are two separate concepts. For instance, a part can have high accuracy but still not be reproducible, or a component can consistently be reproduced despite having poor dimensional accuracy.

Metal stamping is an exceptionally accurate and precise manufacturing process. The dies are highly resilient and can endure extensive usage without noticeable deterioration. Employing standardized processes and an automated approach, particularly with progressive stamping, significantly reduces defects or variations in part dimensions. As a result, the production of precise and accurate parts that meet the necessary quality standards is guaranteed. Precision and accuracy are crucial in industries such as automotive and aerospace, where uniformity is key.

The Versatile Manufacturing method

Custom metal stamping is a highly efficient method for producing intricate shapes and geometries that would otherwise be difficult or impossible to achieve using other forming techniques. Its versatility is one of the reasons why it is a popular choice across a wide range of industries. Metal stamping transforms metal into various sizes and complex shapes, providing a highly customizable metal manufacturing process. The result is a durable and robust metal piece tailored to meet exact specifications.

Adding to the versatility is the range of materials that can be used. It uses a variety of metals to produce high-performance parts with high precision and accuracy. Metal stamping can be done on both ferrous and non-ferrous metals, including low-carbon steel, high-strength steel, galvanized steel, stainless steel, aluminum, copper, brass, and more.

Industries Depending on Metal Stamping

Aerospace and defense – The aerospace and defense industry highly values precision and reliability when creating its components. This is why stamping is a popular method of production. Stamping allows the industry to easily produce parts for wings, fuselages, landing gear, vehicles, firearms, and weaponry. Metal stamping can create complex shapes and designs that meet the highest standards of precision and quality required for aerospace applications.

Automotive – Stamping is also widely used in the automotive industry to produce body panels, brackets, and structural components. Progressive stamped parts are made with high accuracy to meet the safety and performance requirements of the industry.

Consumer Goods – Consumer goods (including electronics) is another field that benefits from metal stamping’s ability to meet precise manufacturing requirements with tight tolerances. Quality is crucial in this competitive industry, and metal stamping consistently delivers components of virtually any shape and form for appliances, HVAC components, lighting, home decor, furniture assembly components, tools and fixtures, brackets, and enclosures.

Medical – In the medical industry, stamped metal components and parts play a crucial role in creating medical components, implantable devices, disposable devices, sterile assemblies, and medical equipment. Medical components must meet safety standards and regulations and performance and durability requirements.

Renewable Energy  –  The renewable energy sector is one of the fastest-growing industries worldwide. As the international community becomes more environmentally conscious, the demand for specialized components used in solar and wind will continue to increase. Brackets for wind and solar energy and bi-polar plates and other components for fuel cells are commonly made using metal stamping.

Working With A Trusted Metal Stamping Manufacturer

Die-Matic has extensive experience across industries and offers full-service capabilities to take you from prototype to completed assembly.   No matter what type of stamping your product requires, we will work with you to design the most cost-effective solution. Contact us today to speak with one of our stamping experts.

The post Why Custom Stamping Metal Parts Is A Preferred Solution appeared first on Die-Matic Corporation.

This guide isn’t going to get into economic forecasts, politics or international conflicts. You can get all of that from the news (if you wish). We’re not going to contribute to the doom and gloom, nor are we going to give “hot takes” or bold predictions. Instead, we’ll provide an objective rundown of the key factors that seem likely to impact manufacturing and precision metal stamping purchasing throughout the year. Here are the trends we’re seeing right now:

1. Onshoring Accelerating

Now in the fourth calendar year of the pandemic, most supply chains aren’t coming to screeching halts like they were early on – but manufacturers remain wary and vulnerable, especially when dealing with international suppliers. To mitigate the risks of further and future supply chain disruptions, and in tune with broader U.S. government initiatives for a more robust supply chain domestically, many manufacturers are bringing jobs back to the U.S., aka onshoring.

While onshoring can certainly be seen as a good thing overall, it’s not without its own potential shortcomings. More domestic production means more transportation and logistics are required, leading to possible delays and higher costs. Weigh the costs and options upfront to determine whether onshoring is truly the best financial decision for your business.

2. Labor Shortages Continuing

In the age of remote and flexible work, it’s difficult to attract skilled workers to traditional manufacturing jobs. Onshoring compounds the issue because you’re creating more jobs that are difficult to fill. The manufacturing talent pool in the U.S. has long been declining, even before COVID. According to Deloitte and The Manufacturing Institute, the U.S. could see 2.1 million manufacturing jobs unfilled by 2030. Labor is clearly a persistent challenge that manufacturers will have to navigate, potentially shutting down facilities at times and/or leaning on outsourced suppliers to fill workforce gaps.

3. Robots Assisting

Remember, 2023 is the year of creative solutions. If your business has made it this far, you can get through any rough patches ahead if you’re proactive and, once again, creative. Now is a good time to take industrial robotics seriously. We’ve done so ourselves at Die-Matic by investing over $500,000 into robotics in 2022 alone. The robots helped fill immediate labor voids while augmenting our staff and bringing our business into the future. Experts generally agree that robotics will continue to become more commonplace in manufacturing facilities. Given the current labor gap, 2023 could be a big year for adoption.

4. Material Costs Fluctuating

The huge price spikes for raw materials are hopefully behind us for the foreseeable future. That said, eroding prices for certain materials – particularly steel – are still a cause for concern and will be important to monitor. If or when prices drop too low, steel mills will begin shutting down to decrease supply and increase demand. This happens cyclically and it’s looking like that cycle may be imminent in 2023. Whenever supply tightens, it can disrupt production schedules, as seen in the automotive industry during the ongoing microchip shortage (which, by the way, doesn’t appear to be letting up quite yet).

5. Suppliers Problem Solving

The trends above have something in common – the need for a supplier that operates more as a partner to flex with you as things change. Will your supplier make challenges disappear? No, but they can help address and work around them. Can they take a financial beating on your behalf? Of course not, but in the current conditions, a little bit of flexibility and foresight will go a long way. For example, if you have a long list of projects on the books for the year, we can consider purchasing materials further in advance to lock in current prices.

With 65 years in business supporting leading brands across many different markets with high-quality precision metal stamping, Die-Matic has an extra advantage in its experience and versatility. We’re here to help you succeed in 2023, no matter what the year throws our way. Request a quote today.

The post 5 Trends Buyers of Precision Metal Stampings Need To Know in 2023 (#5 Is a Must) appeared first on Die-Matic Corporation.

Determine if You Need a Partner or a Supplier

The first thing to decide is what type of metal stamping manufacturer you want to work with. Both partners and suppliers may have the capabilities you need, but there is a difference between the two. A supplier provides transactional services and nothing more. Conversely, a partner will collaborate, proactively offer suggestions for improvement, and provide assembly and other value-added services. When you are in a partnership, the company becomes an extension of your business.

Define Your Project Requirements

Before reaching out to a potential stamped metal parts manufacturer, you must clearly understand your project requirements. Things to consider include the following:

• Design assistance – You won’t get design assistance with a supplier, but a partner can off pre-production engineering and technical expertise to ensure your project can be manufactured to your specifications and the components will function as intended.
• Prototypes – The prototyping process should be consultative, well, to identify improvement opportunities and help you avoid costly delays and problems. Having the same manufacturer build your prototype and your production runs streamlines the process. If a prototype is built by a design house or other company, the design may need to be changed for production to adapt to the manufacturer’s equipment, creating delays.
• Tolerances – Tolerances help manufacturers understand the level of precision required. Be realistic about tolerances because unnecessary tight tolerances can drive up costs.
• Material – Identify the type of material you need for your part. Metal stamping uses a variety of metals and alloys to produce high-quality, consistent parts. Common types of metal include low-carbon steel, high-strength steel, galvanized steel, stainless steel, aluminum, copper brass, and more. When choosing a suitable material, it is essential that the part use and environment, as well as compatibility, be considered.
• Production volume – Consider your part volumes initially and annually. Metal stamping requires a tooling investment, so very low volumes may not be suitable for metal stamping.
• Timelines – Have an idea of when you need your parts but have realistic expectations. Remember that tooling must be built once the design is finalized. However, with that said, some stamped metal part manufacturers run their operations more efficiently and may be able to meet a shorter timeline.

Define Your Expectations for Your Stamped Metal Parts Manufacturer

Defining the component requirements is only part of what will make your partnership successful. List the things that have been pain points for you in the past, even if they were minor. Unresponsiveness, late orders, lack of technical expertise, poor quality control, and inefficiency are just a few of the characteristics that can derail a program and leave a bad taste in your mouth. Also, list what you appreciated about them or your expectations for your metal stamping partner. Prioritize your list to quickly identify which things are non-negotiable and what you are more flexible with. Finding the perfect partner is the goal, but depending on how long your list is, you may need to compromise.

Research Potential Manufacturers

Use multiple resources to research metal stamping manufacturers, such as online resources, industry organizations (e.g., Precision Metalforming Association), and referrals from trusted sources. Take note of location, capabilities, and services to create a shortlist. Ensure they are a well-established company – they have probably endured challenging times and will be more financially stable, and they will likely have more experience to draw from when it comes to problem solving. Once you have a short list, you can take a deeper dive into the company,

Evaluate Technical Capabilities

Once you have a short list, you can dive deeper into their capabilities, quality, and other services you may require. When speaking with them, verify the items that put them on your shortlist. Other key aspects to consider are:

Equipment and capabilities – If they don’t have the capabilities you need, it will be a no-go from the start. Also, look at their equipment. Are they investing in the best equipment, technology, and processes? Quality equipment can usually predict better quality products, precision, and cost-effectiveness.

Quality assurance – Look for a partner with an established and documented quality system. Certification to ISO 9001, and IATF 16949 for automotive, means they have a quality management system and are committed to meeting customer satisfaction requirements and delivering products that meet quality specifications.

Engineering support – Whether or not you think you need engineering support, it can bring cost savings and increased efficiency through recommendations to improve part performance or manufacturability.

Evaluate Partnership Potential

One way to tell if they have what it takes to be a good partner is by assessing their responsiveness and communication – a collaborative working relationship should be two-sided. You can determine the company’s responsiveness and communication through initial emails and phone calls. If they are slow to respond or don’t answer your questions in a reasonable time before they get your business, imagine what it will be like after securing it.

Do they seem to be collaborative? Ask about their project management approach and involvement with design processes. Ask for proof that they are experts. Can they provide examples of similar challenges? How did they identify the problem if it wasn’t brought to them, and how did they find a solution?

If possible, visit the manufacturer’s facility. This will provide an opportunity to see how organized they are and how well they seem to be running; evaluate their capacity, equipment, and quality system; and speak directly with engineers. You can learn a lot about a company by walking its manufacturing floor.

Request a Quote

Request quotes from the manufacturers on your shortlist, providing detailed specifications and requirements for your project. Compare the quotes in terms of pricing and lead times, but keep in mind total costs. The manufacturer should want to review the quote with you and explain anything you don’t understand. Remember the adage, ‘You get what you pay for.’

Your Role

If you are looking for a stamped metal parts manufacturer to be a partner – one who will collaborate and treat your project as if it were their own, reciprocity is essential. Responsiveness on your part allows them to serve you better. If they have questions about your project, getting answers quickly will keep the process running smoothly.

Get Timely, High Quality, Innovative Solutions

We understand the importance of partnering with stamped metal parts providers that strive to meet your needs consistently. The implications of choosing the wrong partner are higher costs, supply chain disruptions, unhappy customers, and headaches. When you need expertise and experience to manufacture your precision metal part at a competitive cost, Die-Matic is a partner you can count on!

Take the first step in our partnership by requesting a quote, and experience the benefits of a true partnership!

The post How to Find a Stamped Metal Parts Manufacturer? appeared first on Die-Matic Corporation.

In this article, we’ll explore sheet metal prototyping and the advantages of working with a single vendor for your sheet metal needs, including how it can save time, money, and headaches in the long run.

Why Sheet Metal Prototyping?

While prototyping may not be necessary for all stamped parts, it is ideal for custom parts. Product design is challenging. You will understand the critical importance of having a prototype if you have ever designed a part that doesn’t fit together with another as it should, has assembly holes that don’t line up, doesn’t do what you thought it would do, is challenging to manufacture, or any other number of issues. Just because it looks good on paper (or a CAD file) doesn’t mean it will turn out as expected.

A prototype allows you to test fit, form, and function and its ability to be manufactured. In the software development industry, they use a term called iterative product development. It is a process of designing, testing, and refining a product through a series of iterations. Similarly, in sheet metal prototyping, iterative development involves creating multiple versions or iterations of a sheet metal prototype, testing it, identifying the flaws, and making changes to refine the design until it meets the desired specifications. This process can involve adjusting the dimensions, thickness, material choice, or any other variable that affects the performance or functionality of the sheet metal part.

Using an iterative approach to sheet metal prototyping has several advantages. It allows for faster design iterations and can help catch design flaws earlier in the process, ultimately resulting in a higher-quality final product. Additionally, it can save time and money by minimizing the need for costly redesigns and minimizing the risk of product failure.

In fact, getting the design right early can save a considerable amount of money. The Rule of 10 states that there is an exponential growth of costs over a product’s lifecycle. So, if a product in a perfect scenario can be produced for $X, it will cost $10x to fix a design flaw at the product design stage, $100X during product prototyping, $1000x at manufacturing, etc. Design issues that are not caught early on can have a snowball effect, leading to even more problems down the line. While costs may vary with product or industry, the Rule of 10 is an important principle that underscores the value of investing in quality and preventing errors early in the product development process to avoid costly rework and delays.

Benefits of a Single Vendor

While product design houses may specialize in designing a product, they are not specialists in manufacturing products. Understanding and having experience with the nuances of manufacturing can’t be read in a book. Having your prototyping done by the same metal stamper manufacturing your part has several advantages.

Consistency — Using the same metal stamper ensures that the prototype and final product are made using the same manufacturing process and materials. This can help to ensure consistency in the quality and performance of the product.

Efficiency — The metal stamper will be familiar with the design and manufacturing process, which can lead to greater efficiency in production. Since equipment can vary between fabricators, they will also better understand any potential issues that may arise during production, allowing them to address these issues more quickly and effectively.

Cost Savings — Using the same fabricator can help reduce costs, as the metal stamper will already have the necessary tools and equipment to produce the product. There may also be value-added services that can be performed, such as welding or assembly, that can be done by the metal stamper that a design house wouldn’t know about. This can help reduce the overall cost of production.

Reduced Time-to-Market — Using the same fabricator for prototyping and manufacturing can help to reduce the time it takes to bring the product to market. Your product can move from prototype to production without going through another design review from the metal stamper and potentially have additional design changes not reflected in the prototypes you tested.

Quality control — The vendor will be able to maintain quality control throughout the process, from prototyping to production. This will help to ensure that your product is of the highest quality.

Flexibility — The vendor will be able to quickly accommodate changes to your product. They can make changes to your prototype or production process as needed.

Communication: Open and transparent communication is critical to a successful product launch. Communicating with a single vendor instead of going back and forth between your designer and your metal stamper if there is an issue will be much less stressful.

Sheet Metal Prototyping Process

If you are new to prototypes, there are a few steps you should be aware of. Working closely with your metal stamper ensures the process runs smoothly. The sheet metal prototyping process can be complex and time consuming. By following these steps, you will have an accurate and functional product to bring to market.

Design — The first step is to design the prototype. Following Design for Manufacturability principles (DFM), engineers will ensure the design includes all the necessary dimensions and specifications, including materials, finishes, and tolerances. You may create multiple designs to determine the most efficient and cost-effective solution.

Fabrication — The prototype can then be fabricated. It may be stamped, or it may be fabricated using other methods.

Testing — Once the prototype is fabricated, it must be tested by the customer to ensure it meets the required specifications. This may involve conducting physical tests, or it may involve conducting functional tests.

Modification — If the prototype does not meet the required specifications, it may need to be modified. This may involve making changes to the design, the materials, or the fabrication process.

Retesting — Once the prototype has been modified, it must be retested to ensure it meets the required specifications.

Production — If the prototype meets the required specifications, it can then be put into production.

A One-Stop Choice For Metal-Stamped Parts

Consider Die-Matic as your one-stop shop for metal-stamped products. We can take you from prototype to production, guiding you through every step of the process. Our engineers will design a prototype (or several) that will ensure your product moves smoothly through production. If you need hardware insertion, welding, coatings, or assembly, we can help with that too! Let’s start building. Give us a call or request a quote online.

The post Why You Should Use the Same Vendor for Your Sheet Metal Prototyping and Production appeared first on Die-Matic Corporation.

It appears that outsourcing metal-stamped parts won’t be slowing anytime soon. The market is expected to reach $310 billion by 2030 at a CAGR of 4.7 percent. If you’re considering outsourcing, we provide ten reasons why you should.

Reduce Total Costs

You can reduce the total cost associated with your product by outsourcing its metal-stamped components. By outsourcing, you don’t have costs associated with capital equipment, materials, manufacturing space, utilities, insurance, technology, and processes. Not only are you eliminating CapEx but also OpEx associated with running and maintaining this equipment.

Additional savings can be found if your stamping partner has full-service capabilities. A partner vested in your success will look for ways to reduce costs in your project by seeing if there is a more efficient way to manufacture it or suggesting different materials that will provide the same functionality and offer the same quality.

Metal stampers who have efficiently run operations have lower costs, so they don’t have to pass the cost of inefficiency on to you. When evaluating total costs, consider avoided costs as well. Greater efficiency can mean consistent on-time deliveries and quality, which can help you avoid costs associated with shipping delays and poor quality (e.g., further delays, failures, returns, and warranty claims).

Focus on Core Competencies

Manufacturing stamped metal parts, when it isn’t your core focus, can be time-consuming. Scheduling production, maintaining equipment, managing materials, and staffing all take time away from other activities. When you outsource components, like stamped parts, you can focus on building your business, putting efforts into R&D, or improving revenue-generating operations.

Tap into Expert Knowledge

You can’t know everything about everything. If you’re building a more fuel-efficient car or more effective medical equipment, you should have to think about how to make a metal-stamped part or fix an issue with it if one comes up. When you outsource stamped metal parts, you are partnering with experts. The metal stampers have worked with parts across industries and may have ideas you haven’t thought of or been exposed to. They also have likely encountered and resolved an uncountable number of challenges, whether it is from the design, the material, or the equipment.

Reduce Safety Risk

There are always risks when it comes to manufacturing. The fewer equipment and people you have in your facility, the less risk of injury and liability. While safety protocols will likely never purposely be ignored, less experienced workers may increase your risks. Additionally, metal stamping equipment requires regular maintenance to operate safely. Outsourcing to a metal stamping partner means you don’t have to be responsible for maintaining this equipment, reducing the risk of equipment malfunction or failure. However, it is essential to ensure that the metal stamping company selected has a good safety record and follows appropriate safety protocols to minimize the risk of accidents and injuries.

Take Control of Your Supply Chain

Supply chain disruptions can shut down your product line or require you to maintain safety stock, which has associated carrying costs. Also, because your stamping partner has developed supplier relationships and buys in larger quantities, they will have an easier time getting raw materials, and better pricing, than you might.

However, not all metal stampers are the same. So if your supply chain is a concern, check on on-time delivery and quality metrics as well as financial stability. A less stable company puts you at risk.

Improved Efficiency

A metal stamping company that has been in business for decades knows the ins and outs of metal stamping and will have built efficiency into its processes. Look for a partner that follows lean manufacturing principles and looks for continuous improvements in their operations.

If you are manufacturing and selling HVAC equipment or consumer appliances, that will be your focus, not creating efficient manufacturing processes for stamping the brackets or other metal components your products need. When you outsource with a trusted metal stamping partner, the metal components will be there when you need them, allowing you to operate more efficiently.

Increase Capacity

Reduce the risk of overproduction or underproduction, which can lead to inventory management issues. If you can’t keep up with demand, consider outsourcing instead of expanding operations. Your metal stamping partner can act as an extension of your company while solving production scheduling problems you may be encountering.

In addition to having the ability to scale your operations quickly up or down as business fluctuates, outsourcing may also allow you to add additional services. Choosing an efficient metal stamping partner with extended capabilities can add to your bottom line.

Eliminate Labor Challenges

Finding skilled labor willing to show up for work every day has become a growing challenge. Labor shortages can increase labor costs as companies compete to attract and retain workers. When you outsource, the issue of labor is shifted to your partner. Outsourcing stamped metal parts can provide cost savings by using the expertise of metal stamping professionals and avoiding the need for expensive in-house hiring and training.

Get Quality Stamped Metal Parts

Aside from understanding stamping equipment and metallurgy, an outsource partner will intuitively and quickly notice if meeting a spec will be a problem. They will have quality processes to ensure your component’s critical characteristics are produced within spec. When you outsource, you are not responsible for developing and maintaining quality processes for metal stamping.

Customization When You Need It

If you are stamping parts in-house, you are likely set up to produce specific parts. Your processes and procedures are in place for those parts, and it might be challenging to change and disrupt production with customization, particularly if you need to purchase special equipment or materials. For example, if you need a different coating or finish on a part, a metal stamper is versed in providing customized solutions and will offer a variety of surface finishes. Or if you want to have a part welded instead of riveting parts together, you won’t have to buy equipment and hire a welder; your metal stamping partner can accommodate the change.

Die-Matic Premier Provider of Stamped Metal Parts

At Die-Matic, we don’t just claim to understand progressive stamping; we’ve been perfecting it for over 60 years. Our expertise and experience in precision stamped parts are unparalleled, and we’re committed to providing you with the highest quality products at a competitive cost.

We pride ourselves on being a one-stop shop for all your stamping needs, from engineering and prototyping to secondary operations and assembly. Our team of skilled professionals works tirelessly to ensure that every detail is considered and every part is made to perfection.

But don’t just take our word for it. Our 98% on-time delivery rating speaks for itself, demonstrating our proven track record for punctually delivering products. And with our “just-in-case inventory,” you can rest assured that we’ll always have your back in case of any unexpected delays.

So why take chances with your next project? Choose the partner you can count on for expertise, reliability, and quality. Contact us today to take the first step toward a successful partnership.

The post 10 Reasons to Outsource Stamped Metal Parts appeared first on Die-Matic Corporation.

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What Is Progressive Stamping?

Stamping uses a custom tool and dies installed in a stamping press to bend, punch, pierce, extrude, draw or flange sheet metal to form a part. When several operations are performed, a progressive die is used. Sheet metal in coil form is fed through the press, which has a series of stations performing distinct functions. In addition, in-die tapping and hardware insertion are also possible. Once the sheet metal strip has run all the way through, the parts are cut off. When running a coil of sheet metal, once the first part has progressed through all the stations, a finished part is completed every time the press closes. Depending on both part design and the press size, including tonnage, progressive stamping can produce hundreds to thousands of parts per hour.

Other Metal Manufacturing Methods

In addition to progressive stamping, several other manufacturing methods may be suitable for your project. One of those methods is metal fabrication. Metal fabrication uses shears, punches, and brakes (and sometimes lasers and panel benders) to blank, punch, and bend the metal. It may also involve tapping or thread rolling. While tools and dies are not required, this is more of a manual process and can sometimes take specialized skills or even custom fixtures. For example, when manually bending metal on a press brake, the operator controls the part quality, and back bending (a slightly reversed kink at the edge of the die) can occur if the operator can’t keep up with the press speed as they manually raise the sheet. You may not get a high level of repeatability. Because of the labor involved, metal fabrication may be cost-prohibitive for large runs and better suited to prototypes and shorter runs.

A third method is CNC machining. CNC machining starts with a solid block of metal (as opposed to a flat sheet), and unneeded material is removed through turning, milling, drilling, or grinding to create the finished part. While it doesn’t typically require special tooling, machining can be labor-intensive because they are run one at a time. CNC machining can be expensive and better suited to low volumes. However, machining can produce a part with complicated curves and contours that can’t be done with metal fabrication. Also, depending on the part, it can result in a lot of wasted material being machined off the block.

And finally, cast metal parts are made from molten metal poured into a premade mold or die and allowed to cool. Once removed from the mold, the part is cleaned up to remove casting and grind casting gates. The mold can be reusable or an expendable single-use mold. Because the part must be removed from the mold, care in design is required to ensure this is possible. This method may not work well with highly complex parts. The surface finish is relatively coarse, requiring a wider tolerance.

Does Stamping Make Sense for You?

When deciding the type of process to use for your part, complexity, size, and quantity must be considered. While an investment in tooling is required, this cost is offset by speed, increased quality, and efficiency.

High production rate – Metal stamping is well suited for large volumes. It can produce complex parts in a shorter amount of time than other methods because of automation and the ability to do in-die tapping and insertion, which require additional steps using different methods.

Higher accuracy and precision – Because the process is automated, the first piece produced will be the same as the last. Increased product quality means the risk of having a part fail because of a manufacturing flaw is mitigated.

High material use – Stamping can optimize material usage, requiring less metal and possibly reducing part weight.

Lower production costs – All the above benefits will reduce your total costs. Additionally, at Die-Matic, we will apply design for manufacturability (DFM) principles to your design to ensure you are using the most cost-effective materials and your part is optimized for manufacturing and assembly.

At Die-Matic, we use both large and small presses that allow us to produce a wide range of part sizes that other metal manufacturing methods cannot. Whether your part is 8 feet long or a ¼ inch in diameter, 0.005 in. or 0.875 in. thick, we can cost-effectively bring your part to fruition with precision metal stamping.

We provide full-service capabilities, from prototyping and engineering support to welded and value-added assemblies, saving you time and money. Plus, with a 98% on-time delivery record and “just-in-case” inventory, you can be assured your products will arrive on time.

Whether you are ready to get started or are still unsure that metal stamping is suitable for your product, give us a call. Our engineers are eager to help.

The post Is Progressive Metal Stamping Right for Your Product? appeared first on Die-Matic Corporation.

1. Assembly

A full-service precision stamping provider will have the equipment, expertise and personnel to not only stamp metal but also fully assemble parts to your specifications. If you’re currently receiving parts from a metal stamping supplier and then assembling them in-house or transporting them to a separate vendor for assembly, finding one precision metal stamping partner that does it all can eliminate the extra steps, improve reliability and possibly save you money in the process.

2. Welding

Established metal stamping companies like Die-Matic can deliver precision welded assemblies as well. Whether your product manufacturing calls for spot, resistance, MIG or TIG welding, we’ve made the equipment investments and hired expert welders to turn our stampings into durable, quality welded parts, with no middle vendor in between. Knowing you have precision stamping, assembly and welding services under one roof with one partner can allow you to focus less on logistics and more on your business and customers.

3. Heat Treating

Some metal stampings can benefit from – or may have customer requirements for – heat treatment. There are different types and purposes of heat treatment, such as tempering metal for flexibility or annealing it to improve ductility, but they all tie back to the main goal of altering the metal’s properties for better performance. Between the permanence of and the precision needed for heat treatment, entrusting stamped parts to secondary heat-treating companies adds a layer of risk for compromised quality. A one-stop shop can alleviate those concerns.

4. Anodizing

Anodizing aluminum helps to reduce corrosion while creating the visual appeal of a metallic appearance. It also enables crisp, smooth, repeatable colors. Choosing a metal stamping partner that provides prototyping can mean the difference between integrating anodizing into a streamlined production process vs. having to ship parts to an additional anodizing supplier after stamping. Once again, the latter adds another isolated step in the process, which equates to risks involving both logistics and quality.

5. Coatings

If you’ve already invested in a specific coating line for your products, it might not make sense to transfer that responsibility to your stamping provider. However, if that’s not the case, ask your stamping partner about finishing options. Leading precision stamping companies have a variety of coatings that can enhance any combination of aesthetics, resistance and performance. Stamping and coating go hand in hand, making them the ideal combination to consolidate with one supplier for greater efficiency in production.

6. Zinc Plating

One of the best ways to make metal more resistant to corrosion – and in turn, extend its lifespan by years or even decades – is zinc plating. Like anodizing, zinc plating also comes in different colors. For a metal stamping company with zinc plating in its repertoire, applying a thin extra coating of zinc onto stamped parts is a relatively easy and cost-effective value-added service. Plating can be done before or after stamping, depending on the use case and requirements.

7. Teflon

Consumers know and love Teflon® for its non-stick, temperature-resistant and long-lasting qualities in cookware. The popular coating is also integral in many other industrial applications including automotive, construction, medical devices, electronics and more. If your production entails Teflon-coated stampings, the right partner will be able to deliver the completed coated parts rather than stampings that must later go to a Teflon coating services company.

Simplify Your Supply Chain

Value-added services from a full-service metal stamping partner help boil down your production logistics. Whether it’s assembly, welding, coating or any of the other services mentioned above, getting more from your metal stamping provider can lead to labor savings, logistics efficiencies and smoother operations all around for your business. Learn more about what to look for in a precision metal stamping partner and discover the many ways Die-Matic can add value to your production program. Request a quote today.

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