Metal stamping is a high-speed, cost-effective manufacturing process that converts flat metal sheets into finished parts using dies and presses. It's the preferred process for high-volume production of metal components — from tiny electronic terminals to large automotive body panels.
This guide covers metal stamping processes, die types, materials, tolerances, and how to optimize parts for stamping.
The most common high-volume stamping process. A metal strip feeds through a series of stations — each station performs one operation (pierce, cut, bend, form) until the finished part is cut from the strip at the final station.
Advantages: - Extremely fast (500-1,500 strokes per minute) - Minimal labor (automatic feeding) - Consistent quality (all operations in one tool) - Ideal for volumes 50,000+
Individual workpieces move from station to station using mechanical transfer systems. Used for larger, more complex parts.
Advantages: - Handles larger parts than progressive - Allows more operations per part - Easier die maintenance (individual die sections)
The punch pulls the metal sheet into a die cavity, forming a deep, cup-like shape. Used for battery cases, cans, sink basins.
| Parameter | Range |
|---|---|
| Draw depth | Up to 3× diameter (single draw); can exceed with multiple draws |
| Wall thinning | Can exceed 50% at corners |
| Applications | Battery cases, hydraulic cylinders, kitchen sinks |
A specialized stamping process that produces parts with perfectly smooth edges (no die break). Uses a third V-ring action to clamp the material.
Advantages: - Smooth edges (no secondary deburring) - Tight tolerances ±0.01mm - Flat parts (no distortion)
| Die type | Description | Typical volume | Relative tool cost |
|---|---|---|---|
| Single station die | One operation per press stroke | 1,000-10,000 | $ |
| Compound die | Multiple operations in one station | 5,000-50,000 | $$ |
| Progressive die | Multiple stations, continuous strip | 50,000-10M | $$$ |
| Transfer die | Individual parts between stations | 20,000-500,000 | $$$ |
| Line die | Multiple presses with separate dies | 10,000-200,000 | $$ |
| Fine blanking die | V-ring, smooth edge | 10,000-500,000 | $$$$ |
| Material | Gauge range (mm) | Formability | Strength | Typical use |
|---|---|---|---|---|
| Cold rolled steel (DC01/SPCC) | 0.3-3.0 | Excellent | Good | Brackets, enclosures, frames |
| Hot rolled steel (DD11/SPHC) | 1.5-6.0 | Good | Good | Thicker structural parts |
| Galvanized steel (DX51D/SGCC) | 0.5-3.0 | Good | Good | Corrosion-resistant parts |
| Stainless steel 304 | 0.3-3.0 | Fair | Good | Medical, food equipment, automotive |
| Stainless steel 301 (full hard) | 0.2-2.0 | Fair | Very high | Springs, clips, battery contacts |
| Aluminum 5052 | 0.4-3.0 | Excellent | Moderate | Electronics, automotive panels |
| Aluminum 6061 | 0.8-3.0 | Fair | Good | Structural parts (better machined) |
| Copper C110 | 0.2-2.0 | Excellent | Low | Electrical terminals, bus bars |
| Brass C260 (cartridge brass) | 0.2-2.0 | Excellent | Moderate | Connectors, ammunition, decorative |
| Spring steel (C75S/SK5) | 0.2-2.0 | Fair | Very high | Springs, clips, washers |
| Phosphor bronze | 0.1-1.5 | Good | Good | Electrical contacts, springs |
| Draw depth ratio | Number of draws needed |
|---|---|
| Up to 1.5× diameter | Single draw |
| 1.5-2.0× diameter | Two draws |
| 2.0-2.8× diameter | Three draws |
| 2.8×+ diameter | Annealing between draws |
| Feature | Standard (±mm) | Precision (±mm) |
|---|---|---|
| Part dimensions up to 100mm | 0.15 | 0.08 |
| Part dimensions 100-300mm | 0.25 | 0.12 |
| Hole diameter (pierced) | 0.08 | 0.03 |
| Hole-to-hole center | 0.15 | 0.08 |
| Bend angle | ±1° | ±0.5° |
| Flatness (per 100mm) | 0.25 | 0.12 |
| Burr height | 0.1mm max | 0.05mm max (fine blanked: no burr) |
| Factor | Cost impact | Why |
|---|---|---|
| Material thickness | Progressive below 3mm is efficient; above 3mm needs heavier press | Increases tonnage requirement |
| Part complexity (number of stations) | More stations = more expensive die | Progressive dies cost $5,000-50,000+ |
| Tolerance | Precision adds 20-40% to die cost | More stations, more careful construction |
| Volume | High volume amortizes tool cost | Die cost spread over more parts |
| Material type | Stainless/high-strength wears dies faster | Advanced tool steel coatings needed |
| Surface finish | Secondary operations add cost | Vibratory finishing, deburring, plating |
| Factor | Metal Stamping | CNC Machining | Sheet Metal Fabrication |
|---|---|---|---|
| Best volume | 5,000-10M | 1-1,000 | 10-10,000 |
| Per unit cost at 100K | $0.05-0.50 | $5-50 (not practical at 100K) | $0.50-3.00 |
| Tolerance | Excellent (±0.05mm) | Excellent (±0.025mm) | Good (±0.2mm) |
| Setup cost | High (die cost) | Low (CAM programming) | Low |
| Material utilization | Good (nesting reduces waste) | Poor (up to 50% scrap) | Good (nesting) |
| Part complexity | Limited by die construction | Almost unlimited | Good |
| Lead time (tooling) | 6-12 weeks | 1-2 weeks | 1-3 weeks |
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