AMFAS provides a wide range of stamped metal parts using many stamping methods. We can provide parts made from progressive stamping dies, punch press stampings, single-stage dies, and deep-drawn parts from transfer presses. We will advise the most cost-effective process for your application or part.
The simplest method of stamping is to use a single stage die to “cookie cut” a part from flat metal stock. The die engages the material and creates the desired cutout. The metal material is repositioned and the process repeats. Parts fall through the base and are collected. Additional dies may punch out additional holes or bend the part into various shapes as needed. This method involves significant handling of the material and parts but offers lower tooling costs. It’s intended for lower volume, prototype, or rapid prototyping of parts.
Punch-press stamping is a step up from single station dies. The punch press may have several die sets where the attendant will move the part from station to station to punch, form, or assemble pieces together. This process involves more tooling and is intended for a higher volume of parts.
Progressing Die Stamping
Progressive die stamping automatically produces parts once the die is set-up. Metal coils are fed into a progressive stamping die through automated means, while a stamping machine repeatedly stamps then feeds the metal coil into the die set. Progressive dies for small parts can be produced at over 2000 pcs/minute. There is almost no direct labor costs other than the set-up and gathering of the parts as they are produced. Although tooling costs are significant; for high-volume production, this offers the most cost-effective production.
Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered “deep” drawing when the depth of the drawn part exceeds its diameter. This is achieved by redrawing the part through a series of dies. The most common uses for deep drawing is to make containers such as aluminum cans. The process uses the cold-working characteristic of most metals, as the metal is stretched, it becomes stronger but more brittle. (This allows us to break a coat hanger wire by repeatedly bending the steel wire back/forth until the steel wire breaks). A metal coil is formed/drawn into the can shape in a series of steps by deforming the metal in incremental steps. As the metal is pushed/formed into the can shape, the metal that was formed becomes stronger but more brittle. This allows the unformed, softer metal to then be pulled/drawn into the can shape without ripping apart. Both cylindrical cans as well as square cans can be fabricated this way.
AMFAS has the capability of supplying all stamping needs, from ¼ inch thicknesses or more if needed in all types of metals. We have tooled hundreds of components, and provided millions of parts with the highest level of quality