Applications of Precision Stampings (Micro-precision Thin Material, Intricate Precision Metal Work and Prototype Design)
Precision stamping is a fast and cost-effective solution for manufacturing large quantities of complex products. There are three major precision stamping applications currently in use at factories across the globe: micro-precision stamping, intricate precision metalwork, and prototype design.
Metal stamping uses high tonnage presses and stamping dies to forge sheets of metal into complete or semi-complete parts. Precision metal stamping improves the speed and accuracy of complex stamping applications by allowing the stamping, folding, drawing, or piercing of a product in a single or series operations.
Benefits and Disadvantages Of Precision Stamping
Precision stamping can be highly automated, making the process well-suited for high-volume because labor costs drop as production levels increase. Upfront tooling costs, however, may render precision stamping ineffective for smaller production runs. Other factors to consider include long lead times and difficulty making design changes once the tools have been created.
What Is Micro Precision Metal Stamping?
Micro-precision stamping is capable of making minute stamps, cuts, bends, and folds in a workpiece. Typically, micro-precision stamping machines support tools with diameters on the micron level. Minimum diameter capabilities vary depending on the particular machine, but .002 inches and .005 inches are common minimum specifications. These micro-stamping combine photo etching technology and 3D computer software to perform highly exact operation
Benefits of Micro Precision Thin Material
Aside from its effectiveness in manufacturing small parts, precision micro-stamping provides numerous other advantages. Some of these include:
• Reduced risk: The inclusion of modular and digital tooling reduces tooling costs.
• Quick results: Thanks to decreased tooling barriers, production can be finished within days.
• Improved flexibility: Changes in product designs are less costly or time consuming than with traditional precision stamping methods.
Intricate Precision Metal Work
Complex products or innovative designs sometimes require a more sophisticated precision stamping procedure. When this is the case, manufacturers often seek out a stamping company that specializes in complex or intricate precision metalwork. These companies will have the considerable experience and advanced technologies necessary for fabricating products with intricate geometries, cuts, folds, or engravings with exact specifications. Some of the technologies that make intricate precision metal working possible include:
• In-die extrusion and tapping: Extrusion and tapping are both performed in the same die to eliminate the need for a weld nut
• Progressive die design: This method applies sophisticated software to improve the die development.
• Deep draw stampings: Deep drawing allows the formation of 3D shapes, such as squares, cylinders, and shells.
• Transfer stamping: This technique reduces costs and secondary operations when stamping complex geometries.
• Class A dies: These dies deliver increased accuracy over steel rule dies.
• Magnified optical devices: Magnified optical devices provide more precise grinding results.
Applications of Intricate Precision Metal Work
Many industries require that produce complex components may benefit from intricate precision metal stamping. Some products routinely fabricated with the help of complex precision stamping techniques include:
• Automotive engines
• Aircraft components
• Machine gears
• Complex electronics
• Telecommunication products
Prototype Design and Precision Stamping
Many precision stamping companies offer prototype design service without the need for expensive dedicated tooling. This helps make prototype design and production cost-effective prior to committing to a final design. Computer programming the stamping equipment also improves the turnaround time. While traditional techniques may take days or weeks to manufacture upfront tooling devices, a company that specializes in prototype design can often deliver same-day or next-day results.
Types of Prototype Design
Prototypes are manufactured through two main processes: single-part transfer and progressive strip prototyping. These processes entail:
•Single-part transfer prototyping: In this process, individual prototype parts are manually moved from station to station. At each station, the part is blanked or metal formed. The main advantage of this method is reduced tooling costs at warehouses that maintain a standard system for design. The disadvantages of single-part transfer include high parts costs and the inability to incorporate miniature parts or complex feature tolerances.
• Progressive strip prototyping: This method differs from single-part transfer in that a progressive die guides the contained stock prototype material through each step in the design process. At each station, the die completes an operation and delivers a complete product at the final stage. Movement of the die along the strip is either manual or controlled by an automatic feeder. Due to increased automation, progressive strip prototyping is good for applications that require miniature part sizes, advanced feature tolerance, and improved production speed.
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