Source: Falcon

Metal stamping is a widely used manufacturing process in various industries across the United States and Canada. From automotive and aerospace to medical sectors, it plays a crucial role in producing metal components.

Metal stamping enables high-volume production and fast turnaround times, but it can be expensive.

In this article, we’ll explore the basics of metal stamping, the types of metal stamping services available, and strategies to reduce metal stamping costs for your business. Continue reading to learn more.

What is CNC Metal Stamping?

CNC metal stamping is a manufacturing technique used to create metal parts by transforming flat metal sheets into various shapes. This process includes techniques like punching, blanking, embossing, bending, flanging, and coining. Many of these operations are performed using cold metal stamping machines, which yield highly accurate results.

As a manufacturing method, metal stamping is known for its low cost and high-speed production capabilities. It allows for large-scale production of identical metal components and is suitable for both short and long production runs.

The Basics of Metal Stamping

Most metal stamping companies follow a standard process. A high-quality sheet of metal is placed into a stamping press (either in coil or blank form).

In the CNC machine, a tool and die surface shapes the metal into the desired form. Depending on the specific requirements, various types of metal stamping processes can be used.

Types of Metal Stamping

There are three primary types of metal stamping: progressive die stamping, fourslide stamping, and deep draw stamping. Read on to learn more about each of these processes:

Progressive Die Stamping

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Progressive die stamping is a metalworking process that uses multiple stations, each with a specific function. As the metal strip moves through the progressive stamping press, it unrolls from a coil and enters the die press.

At each station in the press, a unique cut, punch, or bend is applied. The goal of progressive die stamping is for each subsequent operation to build upon the previous one, resulting in a highly efficient, multi-step process.

Fourslide Stamping

Also known as multi-slide stamping, this method uses four different slides and horizontal alignment. It allows for multiple intricate cuts to be made simultaneously, which is ideal for creating complex components.

During the process, the sheet metal is fed into the fourslide machine, where each tool bends the metal according to the design.

Deep Draw Stamping

Source: Gem Manufacturing

Deep draw stamping forms sheet metal by pulling it into a die using a punch. The term “deep drawing” refers to the process step where the depth of the drawn part exceeds its diameter.

This technique is often used to create parts with varying diameters and is more cost-effective than turning methods. It is commonly applied in industries such as automotive, aerospace, and cookware manufacturing.

Benefits and Drawbacks of Metal Stamping

Like any manufacturing process, metal stamping has both advantages and drawbacks. Below are the key benefits:

 

Precision

Metal stamping is highly precise, ensuring that parts are made with the exact specifications required for safety and functionality.

The process is automated, utilizing stamping simulation technology to detect and correct any flaws before production begins, ensuring flawless results.

 

Cost-Effectiveness

While some other methods of metal fabrication struggle with small or complex parts, metal stamping excels in this area. It allows for the production of intricate parts at a relatively low cost.

Since metal stamping is highly automated, the need for manual labor is reduced, cutting down on overall labor costs and, as a result, lowering the price of the final components.

 

Speed

Metal stamping is a fast process, allowing for a quick return on investment. With equipment capable of thousands of strokes per minute, it is a high-volume, high-speed method ideal for large production runs.

When combined with precision, the speed of metal stamping enables companies to bring new products and innovations to market quickly.

 

Flexibility

Metal stamping is incredibly versatile, capable of producing a wide range of shapes and components, from tiny parts to highly complex geometries.

Drawbacks of Metal Stamping

While metal stamping offers many advantages, it also comes with certain limitations. The main drawbacks include the high initial cost of the stamping presses, die acquisition, and the production of custom stamping dies. Additionally, modifying the die design during production can be challenging.

 

Ways to Reduce Sheet Metal Stamping Costs

Though metal stamping is considered cost-effective due to its automation and speed, the costs can accumulate quickly. Below are a few strategies to help reduce costs:

• Use softer raw materials – Harder materials are more difficult to work with and slow down the process.
• Stick to necessary materials – Choose metals that meet the requirements of your design, rather than opting for more expensive or luxurious options.
• Optimize the process – While fewer operations usually result in lower costs, ensure that the chosen method is the most efficient for your part’s production.
• Consider downstream costs – Cutting costs on raw materials may affect the quality of the final product, so weigh these factors carefully.
• Manufacture in larger volumes – High-volume production significantly reduces the per-unit cost of components.

 

Industries Served by Metal Stamping

Precision metal stamping has been a cornerstone of many industries for decades. Several industries rely on standardized processes to assemble parts and products, including:

What Metals Are Best for Stamping?

Copper is one of the most commonly used metals in stamping, offering versatility for different applications. Other metals such as bronze, nickel, and brass are also popular due to their diverse properties.

Aerospace

The aerospace industry demands precise production processes due to strict safety and regulatory standards. Many aerospace component manufacturers maintain certifications, including MilSpec and RoHS compliance. Some common metal stamped parts used in aerospace include:

Medical Devices

Medical device manufacturing is subject to stringent regulations to ensure the safety of both patients and healthcare providers. Metal stamping is widely used to create components for medical devices such as:

Automotive

In automotive manufacturing, metal stamping is essential for producing structural and functional components for vehicle chassis, electrical systems, steering mechanisms, and more. Examples of parts commonly made through metal stamping include:

Electrical Distribution

In the electrical distribution industry, metal stamping is used to create parts for power switchboards, transformers, and other essential equipment. Some examples include:

Appliances

Metal stamping is also used in the production of various commercial and residential appliances, such as: Freezers, Ice machines, Industrial mounts, Microwaves, Toaster ovens, Trash compactors, and more.

What are the Best Metals for Stamping?

Copper is the most common metal used in stamping due to its versatility in forming various shapes for different applications. Other metals such as bronze, nickel, and brass are also commonly used due to their diverse properties.

 

What is the Purpose of Metal Stamping?

Metal stamping is used to create products like cups, jars, and shells. These products are smooth, with thin walls, and have applications in both industrial