FULL GUIDE TO METAL STAMPING:
COMMON TECHNIQUES, MATERIALS, AND MORE

Full Guide to Metal Stamping

The metal stamping process produces precise, high-quality metal components. The process can create complex custom metal parts across a broad range of industries, including aerospace, automotive, construction, electronics, and medical devices.

The foundation of this manufacturing process is tool and die design, which directly impacts the long-term accuracy and repeatability of the stamping project. With transfer die stamping, progressive die stamping, and other advanced full-service metal stamping methods, manufacturers can efficiently produce a wide variety of cost-effective custom metal stampings.

Knowing how to utilize metal for metal stamping techniques enables manufacturers to produce custom metal parts that adhere to strict specifications while maintaining cost and production efficiency. Engineers and designers must have a thorough understanding of production methods, material properties, and quality control protocols for the best results.

This comprehensive guide examines the significance of metal stamping in manufacturing processes, highlighting its ability to achieve tight tolerances, rapid production speeds, and consistent part quality while meeting the demands of various industries. It also offers valuable insight into material selection and how it can impact the durability, performance, and manufacturability of a metal part.

WHAT IS METAL STAMPING?
THE CORE PROCESS

Metal stamping is a versatile fabrication method that utilizes custom dies and stamping presses to transform metal coils or sheets into high-quality components of various shapes and sizes. Specific types of metal stamping techniques include:

  • Bending
  • Blanking
  • Coining
  • Cutting
  • Embossing
  • Flanging
  • Piercing
  • Punching
  • Shearing
  • Trimming

These metal stamping processes deliver exceptional results for applications that require strict tolerances and complex geometries, and can be tailored to the specific function and design of the metal part.

Custom metal stampings can accommodate a wide variety of materials and production volumes, ranging in size from micro-miniature parts for electronics to large components for the automotive industry. Unlike off-the-shelf components, custom metal stamping requires specialized dies and tools to ensure the utmost level of accuracy and performance.

TYPES OF METAL STAMPING: CHOOSING THE RIGHT TECHNIQUE

Metal stamping relies on various techniques to produce high-quality, precise finished parts that comply with industry-specific regulatory standards and customer requirements. It is essential to select a cost-effective fabrication method that can meet the unique requirements and production volumes of each project in a time-efficient manner.

These are the primary categories of metal stamping that produce custom components.

These metal stamping processes deliver exceptional results for applications that require strict tolerances and complex geometries, and can be tailored to the specific function and design of the metal part.

Custom metal stampings can accommodate a wide variety of materials and production volumes, ranging in size from micro-miniature parts for electronics to large components for the automotive industry. Unlike off-the-shelf components, custom metal stamping requires specialized dies and tools to ensure the utmost level of accuracy and performance.

Single-Hit Stamping

Single-hit dies are relatively simple and inexpensive pieces of equipment, where each stamping station performs a specific stamping operation. An operator loads the metal workpieces and moves them from station to station. This process is ideal for short-run, intricate part production because it is slower than other automated methods but can produce more complex features.

Transfer Stamping

Transfer die stamping uses a single press to operate multiple tools. Each part is removed from its metal strip so it can be rotated and transferred between stations, which shape the part into its desired shape. This technique is often automated to minimize manual intervention and streamline the production process—ideal for high-volume orders.

Progressive Die Stamping

In progressive die stamping, a metal strip advances through a series of stations, performing the following tasks on the same part in the die until the finished component is complete:

  • Bending
  • Cutting
  • Forming
  • Punching

Deep Draw Stamping

This metal forming process employs a punch and die to draw a metal blank into a specified shape, using the following techniques to deform the base material and create recessed features:

  • Blanking
  • Sizing
  • Swaging

It is an ideal solution for components in the automotive and aerospace sectors that require recessed cavities, where the depth of the drawn part typically exceeds the diameter. The efficient process requires fewer raw materials than other stamping methods, contributing to its overall cost-effectiveness and sustainability.

Four-Slide Stamping

This metalworking process is best suited for forming complex flat or round parts with multiple twists or bends over 90º, such as:

  • Brackets
  • Clips
  • Flat springs
  • Retainers
  • Terminals
  • Wire forms

Four-slide equipment utilizes four slides or rams to strike the material, effectively streamlining the production of complex parts and offering the flexibility to run smaller quantities to meet specific manufacturing requirements.

It is an ideal solution for components in the automotive and aerospace sectors that require recessed cavities, where the depth of the drawn part typically exceeds the diameter. The efficient process requires fewer raw materials than other stamping methods, contributing to its overall cost-effectiveness and sustainability.

MATERIALS FOR METAL STAMPING: SELECTION AND PROPERTIES

The success of a precision-stamped metal part depends on selecting the most suitable material for both the stamping process and final application. Material selection influences everything from performance to manufacturability, making it a crucial decision early in the design phase.

OEM engineers can benefit from collaborating with metal stamping specialists during initial development to determine the best type of material for the specific application, ensuring compatibility with the selected stamping techniques.

Key considerations in material selection include evaluating the physical and mechanical properties of the metal, such as:

  • Conductivity
  • Corrosion Resistance
  • Elasticity
  • Formability
  • Heat Capacity
  • Machinability
  • Tensile Strength
  • Weldability

The thickness, width, cost, and availability of the material, as well as part performance in the application's operating environment, must also be assessed.

COMMON METALS

Aligning the material characteristics of the following metals with specific manufacturability and performance requirements can ensure reliable, high-quality metal stampings:

Aluminum

Lightweight corrosion-resistant

Gold, Silver, and other Precious Metals

Ideal for high-performance electronics

Brass and Copper

Good conductivity

Titanium

Lightweight, strong, ideal for extreme environments

Nickel Alloys

Durable, heat-resistant