Full Guide to Progressive Die Stamping

Full Guide to Progressive Die Stamping

Progressive die stamping encompasses metalworking methods such as bending, coining, and punching within a single machine. It is an efficient way to modify raw metal materials into cost-effective parts and products for a broad range of applications. At Evans Metal Stamping, our knowledgeable and experienced in-house master toolmakers deliver top-quality progressive die stampings to meet the needs of our customers.

The following comprehensive guide discusses the progressive die stamping process, the benefits of using this technique, and its wide variety of applications. We also provide an overview of the progressive die stamping capabilities available from Evans Metal Stamping.

The Progressive Die Process

Progressive die stamping offers a cost-effective and efficient method for producing large-volume runs by utilizing a progressive die. The die contains several stamping stations that perform unique forming operations as a strip of sheet metal is fed through the machine. Combining the necessary stamping tools into one die set improves the efficiency of the stamping project.

The following components are essential to a progressive die:

  • Die Set
  • Die Buttons (bushings)
  • Punches
  • Punch Holder
  • Plate (section)
  • Pins
  • Slug Clearance
  • Stripper

Progressive dies may also include features such as sub-liners, stop blocks, slides, or sensors. The primary goal of these components is to ensure accurate handling of the material.

Progressive metal stamping follows these steps:

  1. The progressive die is positioned inside a reciprocating stamping press.
  2. The press moves up, bringing the top die with it and allowing the metal strip to feed into the equipment.
  3. When the press moves downward, the die closes to execute the stamping operation.
  4. A finished part is released from the die with each stroke of the press.
  5. The final cutoff station separates the finished parts from the conveying web.

Progressive Die Stamping vs. Transfer Press Stamping

Progressive die and transfer press stamping are similar operations that offer distinct advantages and disadvantages based on the specific demands of an application.

Progressive Die Stamping

In this process, a metal strip moves through a series of unique stamping stations to perform separate functions within a single machine. Each station alters the metal strip before it continues to the next station. The stock strip progressively takes on the desired shape and dimensions as it moves through the workstations. Precision throughout the entire operation is essential for total accuracy and effectiveness. Because all the parts are attached on one strip, this strip must be accurately positioned or all parts could be ruined.

Industries that benefit from progressive metal stamping include electronics, food and beverage, medical, appliances, military, automotive, and more. The process offers the following advantages for these industries:

  • Improved Production Speeds
  • Long Run Lengths
  • Less Scrap Material
  • Broader Design Freedom
  • Increased Production Capacity
  • Shorter Setup Times
  • Higher Repeatability Rates
  • Lower Production Costs
  • Decreased Labor Costs
  • Tight Tolerances

Transfer Press Stamping

This technique is the preferred stamping choice for large parts and applications with complex designs. In transfer press stamping, one press can operate multiple tools. Each part gets removed from the metal strip in the first station, allowing it to be freely shaped and transferred by each transfer die until completion.

Previously, these procedures required multiple manual transfers and presses, but automation has streamlined the transfer process into a single operation. Transfer press stations can produce the following:

  • Threading
  • Ribs
  • Knurls
  • Cutouts
  • Pierced Holes

Transfer die stamping is ideal for low-volume production runs, offering better versatility and affordability when compared to progressive die stamping. Transfer die stamping can create complex geometries, intricate parts, and larger components with increased cost efficiency due to its lower tooling costs and reduction of scrap waste.

Industries enjoying the benefits of transfer die stamping include agriculture, automotive, electronic, medical, transportation, and more.

Types of Progressive Die Stamping Machines

The type of tooling and press used determines the type of progressive metal stamping machine.

Type of Tooling

Progressive die tooling is necessary to perform all the metalworking operations on the metal strip. Carbide, compound, and forming tooling are also used to execute specific stamping requirements.

Type of Press

Progressive die stamping machines can include the following types of presses:

  1. Mechanical Press: The primary type of precision stamping machinery
  2. Hydraulic Press: A precision stamping machine that provides specialized features
  3. Stamping Press: Equipment such as a straight-side progressive press can deliver top-quality progressive die stampings

Our Progressive Die Stamping Capabilities

Since 1948, Evans Metal Stamping has offered precision custom tool and die design services. With over 200 years of combined tool and die expertise, our experts utilize in-house manufacturing equipment to produce tolerances of less than ±0.001 in.

As an ISO 9001:2015 certified company, Evans Metal Stamping offers high-quality tool and die design and repair services, along with the following metalworking capabilities:

  • Progressive Die Stamping
  • Transfer Press Stamping
  • Blanking
  • Coining
  • Draw
  • Forming
  • Hand Transfer
  • In-Die Electronic Sensors
  • Secondary
  • Single Hit
  • Swaging Dies

Progressive Die Stamping by Evans Metal Stamping

At Evans Metal Stamping, we offer high-quality progressive die stamping to meet the specific requirements of a broad range of applications and industries. We can deliver a high number of parts with a quick turnaround time, regardless of the complexity of the design, offering industry-leading stamping services for small, prototyping projects, high-volume production runs, and everything else in between.

Our precision metal stamping presses can reach top speeds of 1,200 strokes per minute and have stamping capacities that range between 30 and 1,000 tons. Partnering with Evans Metal Stamping provides customers with the following benefits:

  • Decreased Lead Times
  • Cost Savings
  • Reduced Overall Supply Chain Risk
  • Cyber Security Compliance
  • Improved Communication
  • Scalable Production
  • Local And Secure U.S.-Based Supply Chain

Our other capabilities at Evans Metal Stamping include tool and die building, metal stamping, design engineering, welding and finishing, and machining services. Request a quote to get started on your progressive die stamping solution.