Best Custom Metal Stamping Companies in China

The Basics of Metal Stamping

Metal stamping is a versatile manufacturing process that transforms flat metal sheets into precise shapes. It utilizes various metal forming techniques, such as blanking, punching, bending, and piercing, among others, to achieve its complex results.

The China market offers numerous metal stamping companies catering to the automotive, medical,aerospace, and other industries. As global demand increases, there is a growing requirement for efficient, high-volume production of intricate components.

This guide provides expert guidance on best practices and commonly used formulas in the design process for metal stamping, including strategies for reducing costs while designing parts.

Stamping Basics

The stamping process, also known as pressing, utilizes either flattened sheet metal in the form of a coil or a blank, which is then placed into a stamping press. Within the press, a tool and die surface work together to form the metal into the desired shape. Stamping can include techniques such as punching, blanking, bending, coining, embossing, and flanging, all used to shape the metal precisely and efficiently.

The process of forming the material requires the expertise of stamping professionals who use CAD/CAM engineering technology to design tooling. These designs must be precise to maintain proper clearance for punches and bends, ultimately ensuring optimal part quality. The design process is complex and time-consuming, as a single tool 3D model can contain hundreds of parts.

After establishing the design of the tool, the manufacturer has access to a range of machining, grinding, wire EDM, and other manufacturing services to finish production.

You can get more professional information about stamping at wiki.

Types of Metal Stamping

The most common metal stamping techniques are progressive, fourslide, and deep draw.

Progressive Die Stamping

Our product, progressive die stamping, utilizes multiple stations that serve various essential functions.

First, the strip metal is fed through a progressive stamping press, unrolling steadily from a coil and into the die press. At each station in the tool, a different cut, punch, or bend is performed, building upon the work of the previous stations until a finished part is produced. This process is integral to the production of quality products.

A manufacturer may need to frequently change the tool on one press or use multiple presses, each performing one necessary action for a finished part. In some cases, secondary machining services were necessary to fully complete a part. As a result, advanced die stamping is the optimal solution for metal components with intricate geometry that require:

Lower labor cost
Faster turnaround
Higher repeatability
Shorter run length

Fourslide Stamping

The Fourslide process, also known as multi-slide, utilizes horizontal alignment and four simultaneous tools to effectively shape the workpiece. This specialized method allows for the creation of intricate cuts and complex bends, making it perfect for manufacturing even the most intricate parts.

Fourslide metal stamping provides various benefits that make it a preferred option for a range of uses. These advantages stem from its differences from conventional press stamping methods. Some of these benefits are:

Versatility for more complex parts
More flexibility for design changes

A fourslide is aptly named for its four slides, allowing for the use of up to four different tools to perform multiple bends simultaneously. When fed into the machine, the material is bent in rapid succession by each tool-equipped shaft.

Deep Draw Stamping

Deep drawing is a method that uses a punch to pull a sheet metal blank into a die, shaping it into a desired form. This technique is known as “deep drawing” when the depth of the final piece is greater than its diameter. It is a practical option for producing components with multiple diameters and is a cost-effective alternative to turning processes that use more raw materials. Common uses for deep drawing include various applications and products.

Aircraft parts
Automotive components
Utensils and cookware
Electronic relays

Short Run Stamping

Short run metal stamping involves low upfront tooling costs and offers a practical option for prototypes or smaller ventures. Manufacturers utilize specialized tooling components and die inserts to shape, punch, or drill the part after the blank is made. While custom forming processes and smaller production sizes may lead to a higher per-piece fee, the lack of tooling expenses makes short run a cost-effective choice for various projects, particularly those with tight timelines.

Manufacturing Tools for Stamping

The production of metal stamping involves multiple steps, including the creation of a specialized tool for product manufacturing.

In the process of creating this initial tool, a designer utilizes a Stock Strip Layout & Design tool to accurately determine dimensions, tolerances, feed direction, scrap minimization, and other important aspects of the design.

Tool Steel and Die Set Machining

CNC technology guarantees unparalleled accuracy and consistency, even for intricate dies. With cutting-edge equipment such as 5-axis CNC mills and wire EDM machines, even the toughest tool steels can be cut with precision and minimal margins for error.

Secondary Processing

Metal parts can be improved in strength and durability through heat treating, while grinding allows for precise finishing and high surface quality of certain parts.

Wire EDM

Wire EDM, or wire electrical discharge machining, utilizes an electrically-charged strand of brass wire to cut metal materials into complex shapes, including small angles and contours. This method is perfect for achieving precise results and intricate designs.

Metal Stamping Design Processes

Metal stamping consists of several processes that form metal, such as blanking, punching, bending, and piercing. Blanketing involves cutting the initial outline or shape of the product to reduce burrs and save time and costs. This stage also determines hole size, shape, and spacing between edges and holes, prior to piercing.

Bending

When designing the bends in your stamped metal part, it is crucial to consider the necessary amount of material. Be sure to properly design both the part and its blank to allow for a sufficient amount of material to perform the bend. Keep in mind the following essential factors:

If a bend is created in close proximity to the hole, it may deform.
Ensure that the widths of notches, tabs, and slots are a minimum of 1.5 times the material thickness to avoid difficulty in creation and potential breakage of punches from excessive force.
Ensure that the design’s corners have a radius equal to or greater than half of the thickness of the material.
Always keep burrs to a minimum by avoiding sharp corners and complex cutouts in your design whenever possible. In cases where these factors cannot be avoided, it is important to note the direction of the burrs so that they can be accounted for during stamping.

Coining

When shaping a stamped metal part, using a stamping machine to flatten or remove the burr on the edges can result in a more refined edge and add strength to specific sections of the part, eliminating the need for manual deburring or grinding. Remember these key considerations when using this technique:

Bend height

A minimum overall height is required for effective formation of bends, typically at least 2.5 times the thickness of the material plus the bend radius.

Plasticity and grain direction

Plasticity refers to the permanent deformation that results from the application of force on a material. Increased plasticity in metals makes them more malleable. Grain direction is a crucial factor in the strength of materials, especially tempered metals and stainless steel. When bending high strength materials, it is important to consider the grain direction to prevent cracking.

Bend relief

Include small notches next to the section to be bent, with a width at least twice the thickness of the material and a length equal to the bend radius plus the material thickness.

Bend Distortion/Bulge

Bend distortion can cause significant bulging, with a size of up to one-half of the material thickness. As the material thickness increases and the bend radius decreases, the distortion and bulging become more pronounced. In some cases, a cut-in or bump-out on the part may be necessary, with a depth of about .005″. This feature is not needed when using compound or transfer type tooling, but it is essential when using progressive die tooling.

Custom Metal Stamping

Custom metal stamping is a process where specialized tooling and techniques are utilized to create parts according to specific customer requirements. It is commonly used in various industries and applications to achieve high-volume production while maintaining precise specifications.

Custom stamped part for vital monitoring equipment in the medical industry.

Chinacustomstamping was approached by a client in the medical industry to create a custom metal stamp for use as a spring and electronics shield in vital monitoring equipment. The stamped part will be specifically designed to meet the requirements and standards of the medical field.

The customer required a stainless steel box with spring tab features, but struggled to find a supplier that could deliver a top-notch design at a reasonable cost and within a feasible timeframe.

In order to fulfill the customer’s specific requirement of plating only one end of the part, we collaborated with a top tin-plating company that created an innovative single-edge, selective plating method.

Through the use of a material stacking technique, Chinacustomstamping was able to effectively cater to complex design requirements, resulting in significant cost savings and shorter lead times by cutting multiple part blanks at once.

Custom Metal Stamping Projects

Our team of design engineers is equipped to handle diverse metal stamping projects for clients spanning various industries. Take a look at a few of our recent projects completed by our skilled engineers at Chinacustomstamping to see the versatility of our custom stamped metal parts.

Stamped Electrical Connector for a Wiring and Cable Application

Upon request, we were tasked with redesigning an electrical connector cover for our client, AFC Cable Systems. Our goal was to provide a superior product at a lower cost, while also reducing lead times.

Using a sample connector cover and a tool provided by the client, our team at Chinacustomstamping was able to reverse engineer the part and its tool. We then designed a new tool to be used in our 150-ton Bliss progressive die stamping press.

The production method was both costly and complex, with certain projects for clients requiring a completed cover while others did not. This resulted in AFC having to create the parts separately and welding them together as needed.

The covers were specifically designed to be used as daisy chain cables within in-floor and under-floor electrical raceways, leading to strict size restrictions due to the complexity of the design.

The use of interchangeable components allowed for the manufacture of the part in one whole piece, instead of producing two separate pieces as per the client’s previous method.

This resulted in a total cost reduction of 80% for a 500,000-piece order and shortened the lead time from 10 weeks to four.

Finding the Best Custom Metal Stamping Companies in China

For top-tier metal stamping, trust a proven and reputable firm. The industry is currently seeing a surge of new players, some experienced and others not as reliable, drawn in by the appeal of low prices.

Chinacustomstamping specializes in high-volume progressive die metal stamping production and adheres to ISO 9001:2015 quality standards, utilizing state-of-the-art equipment and expertise.

Custom Metal Stamping Capabilities

Our customized metal stamping service incorporates high-speed presses and progressive dies for optimal cost-efficiency in high-volume production. Additionally, our use of specialized manufacturing cells and automation further enhances our ability to deliver low-cost solutions.

Value added assembly
Progressive Die Stampings
Long-Run, High Speed Stamping

Our company, Chinacustomstamping, boasts a wide range of punch presses, including some that can handle up to 600 ton SSDC. Our press beds are capable of reaching sizes up to 168″ x 54″, while our press strokes can reach a range of 12″. For high volume orders, our production rates can reach up to 50,000 parts per hour, making us a top choice for customers with progressive die stamped parts.

Our facility spans 275,000 square feet and is optimized for efficient material handling. Customers may occasionally request a tour of our state-of-the-art stamping equipment. For a complete list of our equipment or further inquiries, please contact us.

Best Custom Metal Stamping Companies in China