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Precision Progressive Die Stamping
Premiere Custom progressive die stamping for all applications and industries!
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Our Progressive Die Stamping Capabilities
Since 1998,Chengli Hardware has been the industry leader in progressive die stamping. We offer custom progressive die stamping services for clients in a wide range of industries.Our in-house tooling fabrication helps control project costs while ensuring the highest quality standards.
We specialize in manufacturing complicated products, and will produce your small, medium, or large progressive die stamping with the highest levels of precision and quality.
| Features | Capabilites |
|---|---|
| Maximum tooling dimension | Length: 50" |
| Maximum thickness | 0.25" |
| Maximum stamping machine | 350 T |
| Daily capacity | 250,000 pcs |
What is progressive die stamping
Progressive die stamping is a metal stamping process used to produce large quantities of parts with complex geometries. It involves feeding a metal strip through a series of dies, each of which performs a specific operation on the material. As the strip advances, the parts are progressively stamped out until the final product is complete.
This process is often used for high-volume manufacturing of parts with intricate shapes and features, such as electronic components, automotive parts, and household appliances.
Advantages of Deep drawing Stamping
- Faster production: Progressive die stamping allows for the creation of complex parts at a faster rate than other stamping methods. This results in quicker turnaround times and increased productivity.
- Consistent quality: With each stroke of the press, progressive die stamping produces identical parts. This results in a consistent level of quality across all parts produced.
- Cost-effective: Progressive die stamping can produce large volumes of parts with minimal material waste, which reduces material costs. The speed of production also means that labor costs are lower compared to other stamping techniques.
- Versatile: It can be used to create parts from a wide range of materials, including stainless steel, brass, copper, aluminum, and more. It is also capable of producing parts with intricate shapes and features.
- Precision: It uses highly accurate dies and presses to produce parts with tight tolerances and precise dimensions. This ensures that the finished parts meet exact specifications.
Challenges of Deep drawing Stamping
- Higher initial tooling setup cost: Compared to stage tooling, progressive die stamping requires more complex tooling which can lead to higher tooling costs.
- Not be suitable for every part. Parts with complex geometries, irregular shapes or varying thicknesses may not be able to be produced with progressive die stamping. In these cases, other stamping methods may need to be used which can increase costs.
- Requires a higher level of expertise to design and manufacture the dies. This can lead to longer lead times and higher development costs.
- Time-consuming and cost :If changes need to be made to the design or specifications of the part, it may require modifications to the tooling which can be time-consuming and costly.
- The potential for scrap and material waste is higher in progressive die stamping compared to other stamping methods, particularly for shorter production runs. This can add to the overall cost of the project.
Additional Process Employed in Progressive Die Stamping
Progress die stamping involves a variety of processes beyond the basic technique of drawing sheet metal into a 3D shape. These processes can be used to further customize and refine the final part.
- Adding beads, ribs, and flanges to the part’s surface. These raised features can enhance the strength, stability, and rigidity of the part.
- Bulging:stretches and expands metal in specific areas to create a desired shape or feature.
- Coining:compresses the metal in a particular area to create a raised or recessed feature, often for decorative or functional purposes.
- Curling:bending the edges of the metal sheet to form a rounded or curved shape.
- Dimpling creates a small indentation or depression in the metal sheet, usually for aesthetic or functional purposes.
- Embossing:raises or recesses a design or pattern in the metal sheet.
- Extruding is another process that forces the metal through a shaped die to create a continuous profile or shape.
- Hole forming is used to punch or drill holes into the metal sheet for attachment or assembly purposes.
- Ironing is a process that compresses the metal sheet to create a smoother and more uniform surface finish.
- Marking can stamp or laser etch identifying information onto the part, such as part numbers or logos.
- Necking :narrows the diameter of the metal sheet in a specific area to create a desired shape or feature.
- Notching :involves cutting small grooves or notches into the metal sheet, often for assembly or attachment purposes.
- Threading creates threads on the part either by cutting them directly into the metal or by adding a threaded insert.
- Trimming involves cutting excess material from the edges of the part to achieve the desired final shape and dimensions.
How does progressive die Stamping Work?
Progressive die stamping is a highly efficient and precise manufacturing process used to produce complex metal parts in large quantities. The process involves feeding a metal coil into a series of die stations, each performing a specific cutting, punching, or forming operation on the metal strip or sheet as it moves through the die.
As the metal strip advances through the die, each station applies more pressure, resulting in a more accurate and complex part. The process involves a combination of punching, cutting, and forming techniques to achieve the desired shape and specifications of the part.
Progressive Die Stamping Materials
Chengli Hardware works with a variety of materials, including stainless steel, aluminum, brass,steel and copper with material thicknesses 0.1-6.35mm, to provide customized solutions for your unique application.
| Aluminum | Stainless steel | Steel | Brass | Copper | Bronze |
|---|---|---|---|---|---|
| 1060 | 301 | 1006 | C23000 | C110 | Phosphor Bronze |
| 3003 | 302 | 1008 | C26000 | C510 | |
| 5052 | 304 | 1010 | |||
| 5083 | 316 | 1050 | |||
| 6061 | 409 | 1065 | |||
| 6063 | 430 | Tool Steel | |||
| 7075 | 420 | Galvanized Steel |
Progressive Die Stamping Finish
We offer a variety of organic coating solutions to meet our customers’ special requirements. If you do not see the material finish combination you are looking for, please fill the quote sheet, and our experts will help you.
The metal stamping parts are typically deburred and cleaned, with a surface finish that is smooth but not polished or textured.It is characterized by visible tool marks, scratches.
Polishing can improve aesthetics and reduce surface roughness using a buffing or abrasive process.The surface rougness could reach to Ra0.8μm ,even Ra0.4μm.
A process where the surface of the metal is roughened or textured by blasting it with abrasive particles or media, such as sand or glass beads.This can help with grip or visual appeal.
Anodizing is a surface finishing process that produces a protective oxide layer on the surface of aluminum parts.
Type II( MIL-A-8625 Type II), provides corrosion resistance and can be done in different colors, such as clear, black, red, and gold.
On the other hand, Type III anodizing, also known as MIL-A-8625 Type III “hardcoat,” is thicker than Type II and creates a wear-resistant layer in addition to corrosion resistance.
Alodine is a chemical process, used to create a protective layer on the surface of the metal stamping parts, improving corrosion resistance and bonding capabilities.
This involves the surface of the metal stamping parts is brushed with an abrasive material, creating a textured or satin-like finish.
A layer of chromium is electroplated onto the surface of the metal stamping parts, creating a highly reflective and corrosion-resistant finish.
Passivation is a chemical process that removes surface contaminants and creates a passive layer on the surface of the metal part, protecting it from corrosion.
Electrophoresis coating, also named E-coating, is an electrocoating process where the metal is immersed in a bath of paint particles and an electric current is applied to create an even coating. Normally the color is black.
Phosphate Plated is a chemical and electrochemical reaction to form a phosphate chemical conversion film. This process is normally applied to steel materals.
Carburizing is a heat treatment process that introduces carbon into the surface layer of the metal to improve hardness and wear resistance.
A layer of zinc is electroplated onto the surface of the metal stamping parts, providing corrosion resistance and an attractive finish. We could supply white,blue,yellow,green colors.
Nickel electroplating is commonly used to improve the corrosion resistance, wear resistance, and surface finish of metal parts.
Nickel electroless plating is a chemical process that deposits a layer of nickel onto the surface of the metal part, creating a uniform and corrosion-resistant finish.
Powder coating is electrostatically applied to the metal stamping parts, which are then baked in an oven to create a durable and attractive finish. A wide variety of colors are available to create the desired aesthetic.
Liquid paint is applied to the surface of the metal stamping parts, providing an attractive finish but typically less durability than powder coating.
This involves the application of a layer of tin to the surface of the metal for improved corrosion resistance and solderability
Black oxide is a chemical process that creates a dark, corrosion-resistant finish on the surface of the metal part.
PVD is an industrial manufacturing process, i.e., vacuum coating, that gives products a beautiful metallic texture and excellent performance. It applies for metal and plastic material, a kind of expensive finishing process.Gold Plating provides good corrosion and tarnish resistance with excellent solderability
Gold Plating provides good corrosion and tarnish resistance with excellent solderability. Normally the thickness is 0.00002″ – 0.00005″.
Silk printing, also known as screen printing or serigraphy, is a printing technique that uses a woven mesh to support an ink-blocking stencil.
Progressive Die Stamping Tooling Design
The reasonable design of the progressive die directly determines the price, quality and capacity of the product.
According to the material, geometry and batch size of the parts used, analyze if the progressive die could be made.
Based on the part drawing, it is necessary to analyze how many processes are required to complete it, study the nature of each process, and arrange them in a reasonable sequence to ensure efficient production.
The strip layout is the basis for designing a progressive die.
The strength of the die, processing possibilities and other factors should be fully considered, and the hole stations should not be too close to each other.
In the progressive die, the distance that each feed advances is called the step distance. Whether the step distance calculation is correct or not is directly related to the quality and dimensional accuracy of the product.
To guarantee that the part is produced correctly and to reduce the danger of flaws, the press speed should be carefully managed.
In general, the edge of the concave die hole edge should not be less than 30 ~ 40mm from the edge of the concave die shape.
The shape and size and tolerance of the convex die are generally determined by calculation methods.
Choose the suitable stamping machines to make them.
From Prototyping to Production
Chengli offers a wide variety of production volumes for progressive die stamping.
Prototyping
Chengli offers metal stamping prototyping services for customers who need to test the viability of their product designs before moving into production. This service is ideal for customers who need to quickly iterate and refine their product designs.
Low Volume
For metal stamping projects with quantities up to 10,000 units, Chengli offers low-volume production services. Such service is perfect for customers who need smaller metal stamping orders to bridge the development of a product between prototypes and mass manufacturing, or who are looking for customized products.
High Volume
We can accommodate high volume metal stamping projects with quantities in excess of 10,000 units. Our production facilities are equipped to handle high volume production runs with precision and efficiency, ensuring that our customers receive cost-effective solutions.
Short Run Stamping
Short run stamping is often used for prototyping or for fulfilling small orders,typically ranging from a few hundred to a few thousand units.It is commonly used in industries such as automotive, aerospace, and electronics.
Long Run Stamping
Long run stamping is used for high-volume manufacturing applications where consistent quality, high efficiency, and low cost per part are critical.It often requires specialized equipment, automated production processes, and strict quality control measures to ensure that each part meets the required specifications.
Why Use Chengli's Metal Stamping Services?
Thanks to our highly efficient process, we provide quick, accurate tooling and unmatched short-run and long-run stamping.
Cost Advantage
Our metal stamping services are cost-effective due to our advanced manufacturing processes, efficient production techniques, and experienced engineering team. We are committed to offering competitive pricing without sacrificing quality or delivery times.
Manufacturing Capabilities
Our state-of-the-art facility is equipped with a wide range of high-speed stamping presses and other advanced manufacturing equipment. We have the capability to produce complex parts with tight tolerances, and we offer a variety of secondary operations to complete your parts to your exact specifications.
Quality Assurance
We maintain rigorous quality control standards throughout our entire manufacturing process to ensure that every part we produce meets or exceeds customer requirements. Our quality management system is certified to ISO 9001:2015, and we utilize advanced inspection equipment and techniques to verify the accuracy and consistency of our products.
See What Our Customers Say About Us
See what our satisfied customers have said regarding how we fulfilled their requirements.
Progress Die Stamping FAQ
Below you will find the answers to the most common questions we get about the metal stamping process.
What is progressive die stamping?
Progressive die stamping is a metalworking process that involves feeding a strip of metal through a series of progressive stamping dies in order to create a finished part. The dies are designed to perform multiple operations on the metal strip as it passes through each stage, such as cutting, bending, punching, and shaping. This process is highly automated and efficient, making it a popular choice for mass production of complex parts.
What are some advantages of progressive die stamping?
Increased efficiency: Progressive die stamping allows for continuous production of parts, which can improve production rates and reduce lead times.
Reduced waste: This process is highly automated and efficient, which can minimize material waste and lower production costs.
Tight tolerances: Progressive die stamping can produce parts with very tight tolerances, ensuring that each part is consistent and of high quality.
Versatility: Progressive die stamping can be used to produce a wide range of parts in various shapes and sizes, from simple to complex geometries.
Cost-effective: While the initial tooling costs can be high, the per-piece cost of parts produced through progressive die stamping is often lower than other manufacturing processes, making it a cost-effective option for high-volume production.
Consistency: Because the process is automated and highly controlled, progressive die stamping can produce parts with consistent quality and dimensions, minimizing the risk of defects and rejections.
What is the difference between progressive and single die stamping?
Progressive die stamping and single die stamping are two types of metal stamping processes. Progressive die stamping uses a series of dies, each performing a different operation, to create a finished part. In contrast, single die stamping only uses one die to perform all necessary operations.
One of the main differences between the two is speed. Progressive die stamping is generally faster than single die stamping because it uses multiple dies simultaneously. This can result in higher production rates and lower costs per part.
Another difference is complexity. Progressive die stamping can create more complex parts with greater accuracy and precision. Single die stamping is better suited for simpler parts that require fewer operations.
Overall, both processes have their own advantages and limitations, and the choice between the two depends on the specific requirements of the part being produced.
What is the difference between progressive die stamping and transfer press stamping?
Progressive die stamping and transfer press stamping are both methods of metal stamping used in manufacturing. While they share some similarities, there are also some significant differences between the two.
Progressive die stamping is a method of stamping in which a sheet of metal is fed through a series of stations, each of which performs a different operation on the metal. As the metal sheet passes through each station, a new operation is performed, and the finished part is produced at the end of the process. Progressive die stamping is often used for high-volume production runs of parts that require multiple operations.
Transfer press stamping, on the other hand, is a method of stamping in which the metal is cut and shaped in a single operation. A transfer press stamping machine moves the metal from station to station, with each station performing a different operation. Unlike progressive die stamping, the finished part is produced in a single operation.
What products are progressive die stamping great for?
Progressive die stamping is ideal for manufacturing high-volume, intricate metal parts that require tight tolerances and consistent quality. This process is commonly used to produce parts for the automotive, aerospace, and electronics industries, such as connectors, brackets, and terminals. Additionally, progressive die stamping can be used to manufacture consumer products, such as appliance components, hardware, and lighting fixtures. The versatility and efficiency of this process make it a popular choice for a wide range of industries and applications.
Progressive Stamping Application
From prototyping to production, Chengli has been a leading manufacturer of precision metal stamping parts for a wide range of industries.
Gallery of Progressive Die Stamping Parts
We machine low-volume and high-volume production orders for customers in multiple industries: aerospace, automotive, defense, electronics, hardware startups, industrial automation, machinery, manufacturing, medical devices, oil & gas and robotics.
