What is Metal Stamping: Types, Processes & Applications

Metal stamping is an integral process in producing metal parts and components. It’s a manufacturing technique that shapes flat metal pieces into useful objects or components like car bumpers, shells, hardware tools, office equipment, and gadgets.

The stamping process uses specific tools that cut out shapes from sheets of cold-pressed metal and then form the stamped materials into the desired shape.

This article explores the different aspects of successful market stamping projects, covering machine types, material selection, applications, advantages, disadvantages, processes, and more.

Stamping is found everywhere around us today that we may take for granted, but important nonetheless!

Four Typical Types of Metal Stamping

Metal stamping is a form of cold forming that involves various processes to shape metal into different forms.

There are four main types of metal stamping, including progressive die stamping, four-slide stamping, deep draw stamping, and short run or prototype tooling.

Progressive Die Stamping

Progressive die stamping is a metal fabrication process that employs several dies activated together to produce continuous parts from a metal strip.

During progressive die stamping, multiple operations like cutting, piercing, forming, and tracing are engaged as the material passes through individual stations operating simultaneously.

With each passing station, workpieces receive specific cuts or shapes according to their pre-defined design specifications.

Four-slide Stamping

Four-slide stamping is an efficient and versatile method for producing small, complex components.

The process requires a four-slide machine, which has four slides equipped with different tools that are used to shape workpieces horizontally.

Four-slide machines also allow for multiple bends across multiple directions within the same part.

Deep Draw Stamping

Deep draw stamping is used for the deep forming of components with a high degree of accuracy and repeatability. It requires feeding a blank into a die to form it into a desired shape, usually using a punch.

Deep Draw Stamping is an ideal choice for tasks requiring greater depths in part shape than other metalworking processes such as piercing or drawing.

Short Run Stamping

Short run stamping is a form of metal fabrication used in mass production to produce large numbers of identical components.

It’s different from other types of metal stamping because it refers specifically to limited production runs–typically 5,000 parts or fewer over a period of six months or less.

Short-run metal stamping is highly beneficial for businesses looking for low-cost and high-speed manufacturing while achieving uniform parts with greater accuracy than hand-crafted methods can typically provide.

What Materials can be used for Metal Stamping?

The common materials used for metal stamping are copper, steel, stainless steel, brass, beryllium copper, phosphor bronze, aluminum, and titanium.

Let’s explore their characteristics further!

Cobre

Cobre is one of the most commonly used materials in metal stamping. It has good electrical and thermal conductivity, a high strength-to-weight ratio, and excellent corrosion resistance properties.

Acero

Steel is another popular material for metal stamping, as it offers great durability and tensile strength combined with a relatively low cost compared to other metals.

Acero inoxidable

Acero inoxidable provides superior corrosion resistance to regular steel and has remarkable wear resistance capabilities due to its chromium content. Fin stamping machine is a kind of mechanical equipment specially used for producing fins, and its core component is stamping die. Stamping die is used to form fins, which is usually made of high hardness steel and heat treated to improve its durability.

Latón

Brass is softer than copper or steel but maintains ductility and malleability when machined into components needed in intricate designs - such as decorative ornamental pieces or handles for furniture applications. It’s also resistant to water damage because of its zinc content.

Cobre berilio

Beryllium copper combines exceptional electrical conductivity with extreme tolerance towards heat shock, which makes it well-suited for electronic connectors or similar components that require high levels of toughness along with good conductive qualities - even at elevated temperatures.

Phosphor Bronze

Phosphor bronze exhibits superior structural integrity thanks to its ability to resist stretch even under considerable mechanical load from tension stressors. It is an ideal choice for precision springs used across various industries, including medical devices, clocks, musical instrument strings, etc.

Aluminio

Aluminio possesses several advantages relative to other common metals, such as greater lightness (50% lighter than stainless steel), broader adaptability within design frameworks, which allows more freedom in terms of shapes/profiles produced (upright forms are achievable), stronger electricity insulation and excellent fatigue resilience even under repeated use scenarios due its innate springiness.

Titanio

Titanium can encompass numerous beneficial features contingent on specific applications like durable yet compact physical purity, allowing fine tolerances plus uniformly inert behavior remaining unblemished by contamination over prolonged periods.

Nine Metal Stamping Processes

Metal Stamping processes include specific techniques to alter and shape metal components into desired parts or products.

Here are the nine metal stamping processes:

Blanking

Blanking is the first step in a multi-step production process and involves cutting out the desired shape from a blank sheet or roll of metal.

Blank shapes are typically punched, drilled, shaped, or cut from the material to create the outline for further processing, such as drawing. Blanking can produce simple single parts up to complex assemblies with multiple pieces.

While traditional blanking utilizes force combined with die tools to customize shapes, fine blanking employs more intricate tool design and advanced levels of lubrication techniques to ensure precise part finishes and tight tolerances when producing intricate designs.

Fine-blanked parts often require no subsequent operations after they have been produced due to their outstanding accuracy — making them perfect for short runs and small batch jobs where precision matters most.

Piercing

Piercing involves creating holes or other features in the sheet metal using a specialized tool and die surface.

In many cases, piercing helps to create intricate designs or functional features that otherwise could not be achieved with traditional cutting methods alone.

This can reduce waste and save costs for manufacturers since additional processes, such as welding, are eliminated thanks to its high precision level.

Drawing

Drawing involves pulling the metal into a die cavity, forming it into a three-dimensional shape, like a cup or a shell.

Drawing compounds can help reduce friction between the punch and workpiece during forming by introducing lubrication or wear-resistant materials to ensure accurate shapes over long production runs.

Bending

Bending involves deforming sheet metal along a straight line. This can be either a cold bending or hot bending process, depending on the tensile strength of the target material.

Cold forming applies to metals with lower tensile strength and only requires slight force for successful shaping. Hot forming typically uses more powerful forces and applies to tougher alloys or materials with higher tensile strengths.

Common examples of bends achieved through this sequence include corners, cylinders, arcs, and edges.

Air Bending

Air bending is a common way for sheet metal to be bent. This technique involves pressing a flat surface of the material into a die—typically V-shaped—using a punch.

The space between the punch and die allows for more flexibility than bottoming or coining bending techniques and makes it possible to bend large parts with ease.

However, attempting to punch an already bent piece can cause the entire part to deform, so air bending should always be performed after the drawing process.

Bottoming and Coining

Bottoming and coining in metal stamping are two of the most complex yet essential processes for making parts precisely and accurately.

They involve compressing or driving material into die cavities to create a specific shape, such as curves, angles, or hollows.

Bottoming specifically pertains to forming pieces that need tensile strength around bends or edges. It drives materials into snug-fitting dies to create a secure bend when pressed.

Coining involves more intense pressures and is useful for creating precise shapes like thin, sharp lines and intricate patterns on the surface of workpieces using hard steel punches during repetitions.

Forming

Forming refers to the general process of shaping metal into various configurations using a die and punch set.

It's also possible to manually form metals like steel using hammers or pliers when working with comparatively softer materials such as brass and bronze.

Pinch Trimming

Pinch trimming involves cutting away excess material from the vertical walls of a drawn or stretched vessel.

This method uses two hardened dies to pinch the metal sheet between them, which effectively separates the part from the scrap.

You should keep in mind that excessive burrs - sharp edges created on cutouts and holes as part of this process - can be an issue with pinch trimming. However, these can often be taken care of using additional secondary processes such as grinding or filing.

Lancing

By cutting along three edges simultaneously, it allows metals to be more flexible and can make vents or tabs without removing any metal pieces from the original sheet.

In contrast to piercing and blanking, which remove sections of a part, lancing only cuts through parts without separating them from their original form.

This unique operation involves striking the workpiece with one die so that it is sheared and bent at the same time.

Advantages and Disadvantages of Metal Stamping

Metal stamping comes with both advantages and disadvantages. Understanding them is essential for informed decision-making in various industries.

Let's explore the key factors that shape the landscape of metal stamping in production scenarios.

Advantages:

• High Precision and Repeatability

Metal stamping achieves exact tolerances and consistency, which is crucial for producing intricate components in industries such as aerospace and automotive. The process ensures that every part matches the original design specifications.

• Cost-effective for High-volume

For large production runs, the cost per piece becomes increasingly economical due to the scalability of metal stamping operations. This results in lower overall production costs, especially compared to less automated fabrication methods.

• Speed and Efficiency

The automated nature of metal stamping machines allows for rapid production rates, minimizing lead times and increasing throughput. This efficiency is vital for meeting market demands and reducing time-to-market for new products.

• Versatility in Material Usage

This process accommodates various metals, including steel, aluminum, brass, and copper, allowing engineers to choose the optimal material for a given application based on properties like strength, conductivity, and corrosion resistance.

• Minimal Waste Production

Metal stamping often uses materials efficiently, with techniques like blanking and piercing designed to maximize the use of metal sheets, thereby reducing waste and associated costs.

Disadvantages:

• Substantial Initial Tooling Costs

While beneficial in the long run, the upfront investment in dies and custom tooling for metal stamping can be significant, potentially making it less viable for short-run projects or prototypes.

• Design Constraints

There are limitations to the complexity of designs that can be achieved through stamping. Certain geometric features might necessitate secondary operations or alternative manufacturing methods, adding to the overall production timeline and cost.

• Potential for Tool Wear

Over time, the stamping dies can experience wear, leading to the need for maintenance or replacement to maintain the high precision that the process is known for. This can cause downtime or impact long-term costs.

• Material Thickness Limitations

Metal stamping is optimized for certain material thickness ranges; too thin, and the material may tear; too thick, and the process becomes challenging or infeasible without specialized equipment.

• Dependence on Volume for Cost Efficiency

The cost advantages of metal stamping diminish with lower volumes. The break-even point may be too high for companies looking for only a moderate number of parts, leading them to consider alternative manufacturing processes.

How to Choose Metal for Metal Stamping?

When it comes to metal stamping, the right choice of material is essential. Here are some factors to consider when choosing a metal for your metal stamping project:

Material Type: Consider the specific type of metal suitable for your application, such as aluminum, steel, copper, or brass. Each metal has unique properties affecting durability, conductivity, and corrosion resistance.

Material Thickness: Evaluate the thickness of the metal required for your stamped components. Thicker materials may impact tooling and press requirements.

Strength and Hardness: Assess the mechanical properties like tensile strength and hardness needed for the final product. This ensures the metal can withstand intended loads and pressures.

Formability: Examine the metal's formability, as some materials are more ductile and easily shaped than others. This influences the complexity of stamping designs achievable.

Acabado superficial: Consider the desired surface finish for the stamped parts. Different metals may require additional processes for achieving specific textures or smoothness.

Resistencia a la corrosión: Evaluate the environmental conditions the metal will be exposed to. Choose a metal with corrosion-resistant properties if the application involves exposure to moisture or harsh elements.

Cost: Factor in the overall cost of the chosen metal, including material costs and any additional processes required. Balance performance requirements with budget constraints.

Conductividad: For electrical applications, assess the metal's conductivity. Metals like copper are highly conductive and suitable for electrical components.

Recyclability: Consider the sustainability aspect by evaluating the recyclability of the chosen metal. Recyclable materials can contribute to environmentally friendly manufacturing practices.

Tool Wear and Maintenance: Analyze the impact of the chosen metal on tool wear and maintenance. Some metals may be abrasive, leading to faster tool wear and requiring more frequent maintenance.

Availability: Ensure a stable supply of the chosen metal, considering market fluctuations and potential sourcing challenges.

Regulatory Compliance: Check if the chosen metal complies with industry regulations and standards relevant to your application, ensuring product safety and quality.

Heat Treatment Compatibility: If heat treatment is part of the manufacturing process, verify that the chosen metal is compatible with the required heat treatment methods.

Stamping Equipment Capability: Ensure that the stamping equipment can effectively handle the chosen metal in terms of thickness, strength, and other relevant characteristics.

Prototype Testing: Conduct prototype testing with the selected metal to validate its performance and assess any unexpected challenges before full-scale production.

Applications of Metal Stamping

Widely applied in a range of industries, metal stamping plays an integral role in product design and development.

It can be used to produce parts for the aerospace, automoción, medical, electronics, and tool manufacturing sectors, as well as mechanical components for construction projects.

Aeroespacial

• Soportes
• Panels
• Conectores

Automoción

• Paneles de carrocería
• Chassis components
• Piezas de motor
• Terminals
• Wire forms
• Brackets and hangers

Médico

• Devices
• Implants
• Components with tight tolerances
• Instrumental quirúrgico
• Prescription dosing tools
• Components for large equipment

Electrónica

• Conectores
• Lead frames
• Shields for electronic devices
• Computers, laptops, phones
• Instrumentos musicales

Appliances and Consumer Goods

• Household appliance parts
• Consumer goods components
• Washing machine parts

Defense and Military

• Casings
• Soportes
• Connectors for military equipment
• Busbars
• Other customized parts

Construcción

• Componentes estructurales
• Fittings
• Brackets, supports, fasteners
• Screws or nuts and bolts

Industria

• Machinery parts
• Equipment components
• Brackets, couplings, fittings
• Marcos
• Clips, hooks, hinges
• Housings or assemblies

Tool and Die Making

• Integral for tool and die production

Resumen

Metal stamping is a manufacturing process that shapes metal sheets using presses and dies. Operating at room temperature, it crafts precise components without additional treatments.

Cost-effective, it excels in structural integrity, short production times, and precise measurements. Drawbacks include limitations in intricate detailing due to metal stress.

Applications span aerospace, automotive, medical, electronic, and defense industries. Processes involve blanking, piercing, drawing, bending, and more.

Choosing the suitable material is key, and expert guidance is recommended for optimal outcomes.

Preguntas frecuentes

When is Metal Stamping feasible?

Metal stamping is a cost-effective method for crafting precise parts from thin metal sheets like stainless steel, copper, and aluminum. It offers flexibility for various production needs, from high-volume runs to prototypes.

What industries can benefit from Metal Stamping Services?

Metal stamping suits industries like aerospace, automotive, medical, electronics, appliances, tools, defense, and consumer goods.

Why Use DEK’s Metal Stamping Service?

Using metal stamping services can provide numerous production benefits, and DEK's precision metal fabrication is designed to save you time and money while delivering parts with tight tolerances.

The process uses a press to shape flat sheet metal into various designs, allowing clients to take advantage of coldworking techniques like blanking, piercing, drawing, bending, air-bending, and more.

All of these processes are configured for specific shapes that meet customers' needs exactly. In turn, this results in more efficient production cycles compared to machining or fabricating because the tools used are much simpler than those associated with other manufacturing techniques.