Progressive die stamping is sometimes written as “prog die stamping”. It is a manufacturing process that allows large quantities of parts and products to be produced quickly and inexpensively. It is possible to mass-produce metal parts of different sizes and shapes. Progressive die stamping therefore reduces production costs and waiting times.
In progressive die stamping, a metal strip is moved through a number of different stations. Each station then treats the workpiece differently, for example by bending, cutting or embossing it. The part gradually changes size and shape at each station until it reaches its final size and shape. When this process is complete, the finished part is cut out of the metal strip.
Advantages of Progressive Die Stamping
Progressive die stamping offers a number of advantages over other conventional manufacturing processes. Here are some of the advantages of progressive die stamping:
- Faster Production: The progressive die stamping process can produce more parts faster because the raw material can be fed continuously. This is particularly helpful for companies that want to produce large quantities.
- Less Scrap: Since no excess metal is added to the product. Therefore, when the part is made from a sheet of metal, less scrap is produced. In addition, the optimized design of the stamping die also helps to reduce scrap.
- Complexity of Parts: With progressive die stamping, you have more design options. The process can handle a wide range of shapes, from the most basic to the most complex.
- Higher Productivity: Progressive stamping can handle longer runs. This means more parts can be produced in less time.
- Reproducible Processing: Progressive stamping machines use sturdy, high-quality tools. This means they can produce large quantities without damaging the tools. Businesses can therefore use progressive stamping to mass produce high-quality, reproducible products.
- Cost Reduction: Progressive die stamping reduces scrap and speeds up production. In addition, it produces consistent, high-quality parts in large quantities. As a result, it reduces overall production costs when mass production is involved.
- Automation: Progressive die stamping enables automated workflows. This reduces the risk of accidents and saves significant labor costs. This is because fewer workers are needed to produce the parts.
- Tight Tolerances: This unique process can produce large quantities of parts. And it ensures that these parts have excellent precision and accuracy.
progressive die process
The progressive die-stamping process is widely used in the manufacturing industry. It is a highly efficient method of metal processing. It is particularly suited to the mass production of parts and products. A highly automated production process is achieved using a type of die called a progressive die. A progressive die consists of multiple stamping stations that can follow a set process on a sheet metal strip.
The main steps in the progressive die stamping process are:
- Die Manufacturing: The toolmaker designs and builds a progressive die according to specific requirements. This die contains all the tools required for manufacturing. Thus, it eliminates the need to change tools between operations.
- Die Loading: After manufacturing the die, we install it in the press. The die opens when the press moves up and closes when the press moves down.
- Workpiece Loading: Workpieces, such as metal strips or plates, are placed in the die. They are gradually fed into the die as it opens.
- Performing Operations: Individual workstations in the die perform operations on the workpiece. These operations include embossing, stamping, bending, cutting, and more. Each workstation performs its task precisely.
- Ejecting the Part: The workpiece moves through each workstation to reach its final shape and size. The finished part is then ejected from the die and can be cut off the carrier belt.
Progressive Die Stamping Applications
Parts made by progressive die stamping are used in a wide range of applications. They play an important role in several industries due to their efficiency, cost-effectiveness, and high quality. The following are some of the main application areas of the progressive die stamping process:
- Electronics Manufacturing: Manufacture of housings, connectors, conductive parts, etc. for electronic products. The ability to produce the required metal parts at high speed and high precision meets the electronics industry’s requirements for quality and throughput.
- Food & Beverage Packaging: Manufacturing metal lids, cans, and containers for food and beverage packaging. This process is not only efficient but also ensures sealing and hygiene.
- Medical Device Manufacturing: Manufactures critical components such as housings, panels, and brackets for medical devices. We provide parts with high precision and reliability.
- Electrical Appliance and Home Appliance Manufacturing: The company manufactures parts for electrical appliances and home appliances. They make items like sockets, panels, and control panels. Capable of producing complex shapes and structures with a high degree of consistency.
- Automotive Industry: Manufacturing body parts, chassis parts, interior parts, etc. for automobiles. Meets the requirements of low cost, high efficiency, and high quality.
- Aerospace and Defence: Manufacture complex aerospace and defense metal parts. Examples include missile housings, vehicle structures, and sensor assemblies.
- Healthcare: Manufacture healthcare products such as medical equipment, pharmaceutical packaging, surgical tools, etc.
- Mining: Manufacturing mining equipment, screens, and other industrial components for demanding work environments.
Read More:12 Different Uses and Applications for Metal Stamping
Progressive Die Metal Stamping vs. other stamping methods
Progressive die stamping is an efficient and economical metalworking process. It has significant advantages over other stamping methods. This comparison evaluates progressive die stamping against other stamping methods.
Composite Metal Stamping
Composite metal stamping performs all stamping operations in a single pass. Therefore, it is suitable for medium and high-volume production of flat parts. On the other hand, progressive die stamping is suitable for mass production. It may be faster for complex design elements or larger parts.
Transfer Die Stamping
Transfer die stamping requires the workpiece to be separated from the metal strip in the first step. Then, it is transferred between multiple workstations to complete the part. Progressive die stamping is a continuous process. The workpiece does not need to be separated and transferred between workstations. Therefore, it is typically faster and more efficient.
Conventional Metal Stamping
Conventional metal stamping typically uses stage tools for the stamping operation. It has a lower setup cost. Progressive die stamping has a higher initial cost. However, it has a lower cost per part, making it particularly suitable for high-volume production. Conventional metal stamping is suitable for low-volume production. Progressive die stamping is suitable for high-volume requirements.
We have industry experience. Progressive die stamping offers significant advantages in lead times, production times, and overall costs. It is particularly suited to machining the requirements of mass-produced, high-quality parts. You can choose different stamping methods to meet production needs. The choice depends on project requirements and complexity.
We have made a detailed comparison between multi-slide and progressive die stamping in other articles, check it out now!
How Do You Choose Between Progressive Die Stamping and Conventional Metal Stamping?
Conventional metal stamping processes include segmented dies and transfer press dies. When deciding between progressive die stamping and conventional metal stamping methods, cost, output, and delivery time are all factors to consider.
Costs
It is important to consider the cost per unit and the tooling costs. The tooling costs for segmented dies are lower, but the cost per unit is higher. Compared to a segmented die, the tooling costs for a progressive die and transfer press die are higher. However, the cost per unit is lower for both processes.
Production Volume
Progressive die stamping can be used to produce large quantities, for example for projects with more than 50,000 parts. Large quantities can also be produced using transfer press tools. The difference is that the parts are removed from the metal strip in the first step. Stage tools, on the other hand, are ideal for small production runs of less than 50,000 parts.
Delivery time
The project requirements must be considered alongside the project schedule to determine which method is best. In terms of production speed, the segmented dies is the slowest. Progressive die stamping and transfer press dies are faster.
Choose Yonglihao’s metal stamping services
Yonglihao Machinery is a professional metal parts supplier. We offer high-quality, efficient, and cost-effective metal stamping services. Our progressive die stamping services are efficient, high-quality part processing solutions. This process offers multiple advantages over other stamping methods. It is better in terms of lead time, production time, and overall cost.
Yonglihao Machinery can provide versatile and efficient progressive die stamping services. They can serve any industry or project. We focus on meeting customer needs. We provide customized solutions for your manufacturing projects. Contact us today to learn more.