Author Archives: Kevin Duffy

1. How to Avoid Common Issues When Metal Stamping Parts

   August 31, 2023 8:50 pm Leave a Comment

   Metal stamping is a fabrication process used to create unique sheet metal designs. It entails using one or more stamping dies to shape the metal by cutting, piercing, or forming the metal in a certain way. It may involve a single process with at least one die, multiple sequential dies in one machine, or moving the metal material between dies across multiple machines in a process known as transfer stamping.

   Regardless of the method used, metal stamping uses multiple techniques and materials, which is why you must find the right setup for your required metal stamping process.

   Common Problems in Metal Stamping

   Without the right setup, several potential metal stamping issues can arise, but they also have a variety of potential solutions. Knowing what these problems and solutions are will help keep the metal stamping process smooth, efficient, and cost-effective.
   Here are some common metal stamping problems.

   Poor-Quality Stamping

   Low-quality stamping is one of the most common reasons for stamped sheet metal defects. Cracking is one of the biggest issues seen with poor-quality stamping, usually on the edges of stamped parts during cold and hot rolling. Poor-quality stampings can also have:

   • Inconsistent sizes
   • Scratches
   • Fewer holes
   • Deformations
   • More burrs

   There are certain factors that result in poor-quality stampings, such as worn tools, improper tool design, inadequate maintenance, and selection of the wrong materials.

   Tool Wear

   Metal stamping issues could also involve tool wear, making it important to repair or replace equipment as needed. Over time, tools experience a degree of wear that renders them less efficient and effective, which can contribute to poor-quality stampings.

   Some of the potential causes of tool wear include incorrect selection of materials, inadequate maintenance, and overusing the tools.

   Material Selection

   You must also select the right metal to use in your metal stamping process. Different types of metals come with different benefits and disadvantages, influencing their ability to meet certain performance requirements. For instance, you might need a durable and corrosion-resistant material like stainless steel for one application, whereas another application may benefit from using more lightweight aluminum to meet lower weight requirements.

   If you neglect to choose the right materials for your metal stamping application, the process may result in premature tool wear, poor-quality stamping, and other potential problems.

   Solutions to Issues in Metal Stamping

   You can use the following solutions to help avoid the problems discussed above.

   Proper Tool Design

   Tools should have the proper designs and engineering behind them to prevent potential issues with wear and incompatibility with other equipment and workpieces. Proper tool design entails selecting the appropriate tool materials and geometries.

   Correct Material Selection

   You will need to select the right materials for each stamping process to prevent issues like poor-quality stamping. Consider materials based on the ideal properties the part should have, the part’s intended use, and the budget available to spend on stamping materials.

   Regular Maintenance

   Prevent potential tool wear and other common metal stamping issues by performing regular maintenance on equipment. Proper maintenance will involve regularly inspecting, lubricating, cleaning, and replacing any equipment if necessary. Through proper, consistent maintenance, you will expand the life of all equipment and minimize the risk of poor-quality stamping.

   Appropriate Use

   Reduce the risk of overuse in metal stamping by facilitating the proper use of all tools and other equipment. In addition to avoiding tool overload, be sure to use the right metal stamping techniques and refrain from using the tools for anything other than its intended use.

   Metal Stamping Services From Manor Tool & Manufacturing Company

   Choosing the right materials and techniques as well as properly maintaining stamping equipment can help you reduce the risk of potential issues. In turn, you’ll benefit from more efficient processes and high-quality metal stamping parts.

   If you require help with your next metal stamping project, turn to the professionals at Manor Tool & Manufacturing Company. As an ISO 9001:2015 certified manufacturer, we deliver precision metal stamping, deep drawn stamping, progressive die stamping, punching, bending, and more.

   Contact us today to learn more about our metal stamping capabilities, or request a quote to get started on a new project.

2. Metal Stamping Industry Forecast & Analysis

   July 28, 2023 5:45 pm Leave a Comment

   Recent research projects that the metal stamping market will experience a Compound Annual Growth Rate (CAGR) of 4.01% from 2022 to 2027. This represents a marked increase of $31.36 billion USD. This increase in demand is driven by technological breakthroughs in the automotive sector, as well as increased demand for consumer electronics. Metal stamping is widely used in the automotive industry, to construct hangers, brackets, side panels, bonnets, and other components. It is also a key manufacturing method for the telecoms industry, which is predicted to increase its demand for stamped products relating to 5G technology. Read on for a more in-depth look at the metal stamping market forecasts.

   Global Metal Stamping Market Dynamic

   The emergence of next-generation stamping technology is gaining traction on a global scale. The future of metal stamping will focus on minimizing the time and cost of production while increasing production capabilities that accommodate new product developments. Specifically, a growing demand for lightweight vehicles will shift the focus of auto component manufacturers.

   Numerous end-user industries are currently experiencing rapid growth, and the global metal stamping market is also seeing a large opportunity in growing nations. This market expansion is fueled by metal stampings for surgical equipment and implantable devices, however, automotive, aerospace, consumer electronics, industrial machinery, and telecommunications industries are all increasing their demand for stamped components.

   Key Metal Stamping Market Drivers

   The many benefits of metal stamping are driving its market growth. As an automated process, metal stamping reduces labor costs and meets large production volume demands. Its ability to produce precise metal components quickly and cost-efficiently make it suitable for many diverse products and industries.

   Additionally, metal stamping facilitates design flexibility, with its ability to handle tight tolerances and unique, customizable component configurations. These factors are expected to drive market growth during the forecast period.

   Metal Stamping Market: Segmental Overview

   Certain metal stamping processes and end-use applications are expected to see the largest growth during the forecast period. Specifically, blanking is expected to claim the largest revenue share among metal stamping processes. This is due to its accuracy and increased demand from the automotive sector. Blanking’s ability to accommodate mass product lines will also boost its growth in upcoming years.

   Additionally, metal stamping demand from the aerospace and aviation industry is expected to grow significantly during the forecast period. This growth is attributed to an increased focus on safety and the need to meet stringent quality standards. Metal stamping is also capable of producing the lightweight and adaptable components this industry needs to reduce fuel costs and weight.

   Process and Application Insights

   In upcoming years, end-use applications in the automotive, aerospace, telecommunications, and agriculture sectors are expected to see the most significant growth, with blanking and embossing predicted to be the most in-demand processes. Let’s take a closer look at the market predictions for these applications and processes.

   Application Insights

   Metal stamping application insights for the coming years can be segmented into four primary industries that will lead demand:

   • Automotive & Transportation: In 2021, the automotive sector accounted for over 35.5% of revenue for the metal stamping industry. Furthermore, the International Organization of Motor Vehicle Manufacturers reported that in 2020, the production of heavy-duty trucks and LCVs reached 4.3 million and 17.2 million units respectively. High-volume production capabilities are expected to continue expanding market growth in this sector in the coming years.
   • Aerospace: Metal stamping is a durable and cost-effective method of manufacturing aerospace components like frames, channels, and ultra-lightweight parts. This combined with the growing production of fighter and commercial aircraft is expected to propel market growth in upcoming years.
   • Agriculture: Currently, various metal stamping companies are investing in research related to advanced stamping technology for agricultural equipment, such as agricultural automated processing systems. These developments are expected to boost market growth throughout the forecast period.
   • Telecommunications: For telecommunications products, the demand for stamped metal parts that provide enhanced durability is expected to increase, as well as high demand for premium products.

   In addition to these focus areas, growing industrialization in emerging economies will increase the demand for industrial machinery-related products. Specifically, Brazil, South Africa, India, and China are predicted to increase global demand for metal-stamped components.

   Process Insights

   As an integral aspect of automotive manufacturing, blanking is expected to propel sector growth in upcoming years. This is largely due to its ability to accommodate mass production lines. In 2021, embossing was the second-largest process segment for the metal stamping industry, and its demand is expected to continue growing as well, due to its cost-efficiency and versatility.

   Metal Stamping From Manor Tool & Manufacturing Company

   With over 50 years of experience in metal stamping and hard tooling, Manor Tool & Manufacturing Company is a trusted source of high-quality stamped metal products. Whether you need a prototype or a high-volume production run, we can deliver a cost-effective solution that exceeds your expectations.

   We review every part we produce to ensure continued quality and process reliability and perform maintenance on our in-house dies after every production run. To learn more about our capabilities, contact us or request a quote today.

3. 6 Basic Sheet Metal Fabrication Techniques

   June 30, 2023 7:34 pm Leave a Comment

   Sheet metal fabrication is any process that involves assembling or manufacturing raw sheet metal. One or more fabrication processes can be used to produce the desired part, depending on the material and specifications of the project. Clients can choose from metal cutting, welding, bending, machining, punching, and stamping fabrication techniques to create their products. We will explore each metal fabrication technique to help you determine the ideal method(s) for your application.

   Metal Stamping

   Metal stamping fabrication works with various sheet metals. Galvanized alloys, brass, copper, aluminum, and stainless steel stamping can be used to deliver the desired result. Metal stamping is vital to manufacturing and assembling automotive components such as firewalls, doors, hubcaps, and trunk lids. Metal stamping lends itself well to custom designs and features, such as high-performance and specialty components.

   Metal stamping encompasses more than punching holes in sheet metal with a die. When necessary, a stamp and die can lift a sheet metal section, creating raised letters, shapes, and images on the surface. This process works like woodworking and marble relief carving and is used in applications like minting coins.

   Metal Cutting

   Sheet metal cutting is often the first step in metal fabrication. Depending on the project specifications and thickness of the metal, a manufacturer chooses one of the following metal cutting methods:

   • Water jet: A water jet cutter uses a high-powered water stream to cut metals of various thicknesses using a narrow, high-pressure water nozzle.
   • Torching: A high-temperature flame from a cutting torch can cut metals prone to oxidization, including steel.
   • Shearing: A sheet metal workpiece is placed flat and shears cut through it with two large scissor-like blades, pushing the workpiece toward the lower blade. Manufacturers can economically cut thin pieces of sheet metal with small manual shears.
   • Sawing: Band and circular saws can cut sheet metal workpieces that are too thick for torches, water jets, and shears. Sawing is recommended for thick metal because it is time intensive.

   Metal Welding

   Welding metal involves joining sheet metal workpieces together by applying intense heat to bond the pieces. The welding method depends on the equipment available, the metal type, and the material’s thickness. Manufacturers perform sheet metal welding using the following popular methods:

   • MIG welding: A type of arc welding that relies on a continuous wire electrode being fed through a welding gun to generate a welding pool. A shielding gas protects the weld pool from contamination.
   • TIG welding: An electric arc travels through an infusible tungsten electrode to generate intense heat, fusing 8- to 10-mm thick metal sheets.
   • Laser welding: A method that fuses sheet metal workpieces by melting and bonding the metal with a solid-state laser resonator. Laser welding delivers high-quality welds with consistency.

   Metal Bending

   Metal bending is a vital step of sheet metal fabrication. Sheet metal is bent using bending equipment like press brakes and rolling machines. Manufacturers rely on bending to shape the sheet metal into various products, such as by creating configurations like T-shaped corners and 90° angles.

   Metal Machining

   Machining is a subtractive manufacturing process that removes material from a workpiece to create a component. While manual machining is still common, computer numerical control (CNC) machining is increasingly popular due to its speed, consistency, and tight tolerances.

   CNC turning and milling are the most common processes. Turning relies on a stationary, single-point cutting tool to remove material from a rotating workpiece. It is ideal for creating cylindrical pieces with high-precision external and internal elements. Milling removes excess material using a rotating multi-point cutting tool on a stationary workpiece to create a component from start to finish or as a secondary finishing process. Machining provides replicable, accurate, and precise material removal.

   Metal Punching

   Metal punching is a fabrication method that forms, cuts, and punches metal with a punch press as the workpiece passes through it. A metal punching tool combined with a die set offers the versatility to create custom metal workpieces out of various metals. It is a cost-effective and efficient solution for high-volume production.

   Sheet Metal Fabrication From Manor Tool

   Sheet metal fabrication involves six main techniques that can be used separately or in combination to produce the desired part. With over six decades of experience, Manor Tool serves various industries with quality metal stamping and fabrication from our Illinois facility. Contact us or request a quote to discuss your sheet metal fabrication needs.

4. Manor Tool and Mechanical Mustaches Robotics Team

   June 2, 2023 4:40 pm Leave a Comment

   

   Manor Tool & Manufacturing is passionate about meeting the needs of our clients, no matter how many components they need or how unique the end-use application is. Recently, we collaborated with the Chicago, IL, Taft High School robotics FRC team, the Mechanical Mustaches, to fabricate a component for their robot.

   The Mechanical Mustaches had an upcoming regional competition in Wisconsin and needed to build a large and powerful robot. Manor Tool worked with the team to develop and fabricate a part that met all their performance requirements, with delivery that met their timeline requirements. The team’s instructor Anthony Schmidt said in an interview with the Technology & Manufacturing Association that their robot performed well in the Wisconsin FIRST® Regional.

   Robotics FRC Team

   The Mechanical Mustaches are an FRC team, which stands for FIRST® Robotics Competition. FIRST is a global organization that encourages students to build their technological and scientific skills. The acronym is an abbreviation of “For Inspiration and Recognition of Science and Technology.” The organization holds an annual international competition among high school students to build robots that compete in field events involving tasks like balancing on beams, holding onto bars, and other challenges.

   To enter this competition, Taft High School’s robotics FRC team needed to build a robot that weighed up to 150 lbs and was upwards of 6 ft. tall. It required a significant amount of design and programming skills to bring the project to life, including a variety of high-quality stamped metal parts. After collaborating with Manor Tool to obtain a specialized component, the robot was completed and was fit to compete in this prestigious competition.

   Metal Stamping with Robotic Automation from Manor Tool

   At Manor Tool & Manufacturing Company, whether you need to develop a single part or a large production run, we can fabricate your component quickly and cost-effectively using our robotic automation tools. We deploy a robotic arm to automate the movement of stamped parts as they move among various machines during the fabrication process.

   We used this technology during our project for the robotics FRC team. The process is as follows:

   • First, raw material is fed into a press for the initial metal stamping.
   • After the part is formed, it slides down a chute and is inspected by a vision system for accuracy.
   • Next, a robotic arm picks up the part and places it on the die in the second press where the final stamping is performed.
   • Finally, the robotic arm separates the finished part from the scrap material.

   Our automation technology significantly reduces cycle times and allows us to produce as many as 500,000 stamped parts annually. For customers like the Mechanical Mustaches, it ensures they receive their part as fast as possible, and at a highly competitive price.

   Metal Stamping from Manor Tool & Manufacturing Company

   Since 1959, Manor Tool has been fabricating expertly-crafted metal components. We specialize in bending, punching, forming, and deep-drawn stampings as well as hard tooling. After every production run, we conduct die maintenance within our facilities and carry out inspections on every component to ensure reliability in the process and quality. You can learn more about our die maintenance process on our website. If you have any questions, reach out to our team.

5. How Metal Stamping Parts Is a Cost-Effective Choice

   May 19, 2023 9:11 pm Leave a Comment

   Metal stamping parts should be part of your production process if you’re looking for ways to reduce overall costs. Partnering with a skilled metal stamping partner with the right tooling, you can benefit from this fabrication process in a variety of ways—not just in terms of cost. Learn how metal stamping can save your business time and money.

   

   Materials

   Choosing the right materials and using them wisely is key to achieving more cost-effective operations. Here are our tips for utilizing the right materials in the most efficient, cost-effective way:

   1. Material selection — Short-term cost savings must be balanced with maximum part longevity. For instance, the most economical choice long-term may require materials with slightly higher upfront costs, like magnesium or aluminum. A thorough cost-benefit analysis will reveal whether higher upfront costs are to your advantage, or if a cheaper option is perfectly suitable.
   2. Avoid exotic alloys — Without a significant design purpose, luxury or exotic metals are usually not essential to a part’s end use. When possible, choose more readily available and affordable metals, instead of exotic alloys. Modern innovations in metallurgy have made available a wide range of metal alternatives that are very close to higher-end metals in terms of quality, strength, and appearance. For example, high-strength, low-alloy (HSLA) steel is a commonly used material due to its excellent corrosion resistance, low cost, and other properties that closely match spring steel.
   3. Minimize scrap — Arranging design layouts for maximum parts per sheet is key to reducing waste. It also shortens lead times by using fewer metal sheets per run. Each metal has unique tensile strengths and other properties that make them more or less machinable. Your metal stamping partner should work with you to review the best material options for your design.
   4. Buy materials at the right time — Timing is an important factor many metal stamping companies neglect. By buying materials when the market dips, you can maximize purchasing power over competitors who simply buy materials whenever needed.
   5. Secondary processing — Cheaper, less robust metals can sometimes be sufficiently strengthened through secondary processes. For example, we once helped a client replace their aluminum parts with thin embossed steel, which has an equivalent strength and weight but a dramatically lower cost.

   When consulting with your metal parts stamping manufacturer about your design, let them know about:

   • Changes in part requirements
   • Design factors not yet set in stone
   • Potential design modifications

   Process Efficiency

   More complex processes are also more expensive. Generally, reducing the number of times a part must be touched or processed also reduces costs. The major exception is when additional steps using a cheaper material result in a lower cost per part, compared to fewer steps using a more expensive material.

   Designs should also be optimized for manufacturability based on the capabilities and limitations of the metal stamping dies, assembly lines, and other available manufacturing equipment. Tooling experts can then provide accurate predictions of the time required for your manufacturing run(s), allowing you to adjust your project deadlines accordingly.

   Most importantly, experienced metal stamping professionals can quickly test design changes with cutting-edge software, ensuring you catch potential defects before expending time and resources. Reliable quality controls at every stage, especially during pre-production, are essential to achieving maximum cost-effectiveness, shorter lead times, and higher product quality. These benefits can only be achieved by a metal parts stamping specialist who’s taken the time to optimize their process from start to finish.

   Equipment and Tooling

   High-quality metal stamping equipment also improves cost efficiency and lead time. For high-volume productions, four-slide stamping machines and progressive die-stamping are ideal.

   Your metal stamping provider should review your tooling requirements beforehand. They may see opportunities for alterations that lower tooling complexity without any loss in part functionality. This could be as simple as making square holes round, since round holes greatly simplify machining and tooling requirements.

   Alterations can dramatically shorten lead time and maximize cost-effectiveness. Manor Tool’s metal stamping engineers can help you see if design changes could allow the same machine or process to perform multiple functions, potentially saving significant expenses, especially at scale.

   Cost-Effective Metal Stamping Services From Manor Tool

   Metal parts stamping is a cost-effective fabrication process that, when utilized with the right expertise, can streamline your entire production process. It’s not always true that higher quality means higher costs, and by working closely with the experienced metal fabrication experts at Manor Tool, you can boost part quality even as you shorten lead times, lower costs, and maximize ROI.

   Learn more about our metal stamping services. To get started on your metal stamping project, contact us or request a quote today.

6. Metal Stamping Die Design & Maintenance Cost

   December 19, 2022 10:15 am Leave a Comment

   Many factors contribute to determining how much metal stamping will cost to produce your parts at high volume. While most factors such as material, tooling investment, labor, and overall part count are well known, many businesses fail to include the cost of die maintenance in their calculation for overall cost per part. Several aspects of the metal stamping process inherently cause wear. Without a strong die maintenance plan, you’ll end up spending even more than you calculated – because you’ll need to replace your tooling. Here are some areas that contribute to the overall cost of die maintenance.

   Wear Stamping Die Failure Modes

   Your tooling goes through a high friction and cyclical load process to create your parts. This creates natural wear on your die that causes the tooling surface to lose material as the part material is compressed and slides between the surfaces of the die to create your part features. This is called abrasive wear. Excessive abrasive wear can lead to fatigue cracking originating near complex notch features. Adhesive die wear occurs when the heat generated between the die and the part material during the stamping process create microwelds originating from the surface roughness of the two materials, that cause material to be “torn” away from the die. As this process continues the tooling surface is continuously degraded until maintenance is required to maintain part quality. The material hardness of the die, any coatings used, and the overall hardness of the part material determine the amount of wear per strike. Galling is the opposite of adhesive wear and occurs when the sheet metal being formed adheres to the tooling surface. Again, the friction and heat generated in the metal stamping process creates physical or chemical adhesion based on the material and the tool steel used in the die. Abrasive wear, adhesive wear, and galling can be controlled and minimized by using the correct coatings or surface treatments on your tooling – but ultimately, all dies need maintenance from wear.

   Destructive Stamping Die Failure Modes

   When proper manufacturing process best practices or maintenance schedules are not applied correctly, it can lead to more extensive die damage. Deformation of tooling occurs when the compressive force of the press applied to the die exceeds the compressive yield strength of the tool steel used to make the die. While the proper tooling material helps avoid this issue, operator error can create an issue like this that requires extensive maintenance. Chipping of the die can happen when there are excess metal flakes or scrap from cuts that are not properly cleared from the die after a strike. This can also occur by exceeding the strikes that the tooling is rated for, thus surpassing the fatigue strength of the tool steel. Chipping typically appears along the edges or corners of the tool as stress lines carry there from the high contact areas. Cracking of the die happens when the press impact force exceeds the fracture point of the material. In this scenario, sharp corners and radii in a die design enable cracks to form and spread until there is some level of tool failure.

   As your tooling goes through an average of 1,000,000 strikes prior to requiring maintenance, it is designed to handle repetitive thermal and mechanical stress – but even the best dies wear out over time. When maintenance of your die is required, the team must take it offline and take it apart to repair the wear. The tooling for your part needs to be maintained properly so it can continue to produce high quality parts for your business. Planning the down time into your annual schedule allows you to properly care for your die (or multiple dies for progressive die stamping), project your overall cost per part, meet your lead times, and reliably fulfill on orders for your customers.

7. Impact of Material Selection On The Cost of Metal Stamped Parts

   November 18, 2022 5:30 am Leave a Comment

   When sheet metal formed parts are needed in high volume, metal stamping becomes the most viable option for a production process. This acceleration in part count means an even greater focus on per part cost and Total Cost of Ownership (TCO). While many aspects of the part design and metal stamping production process factor into the overall cost, material selection is an area that a business can control and plan to ensure the best possible long term per part price for their metal stamped parts.

   Material Wear on Die

   Every strike of the press causes wear on the die or dies involved in the metal stamping process. The material used to make the end components affects the timeline for die tooling surface wear due to the friction produced in the forming process. The most common materials used in metal stamped parts are steel, stainless steel, copper, brass, nickel and aluminum. Softer and more malleable material like copper will cause less wear on the die, while harder and stronger materials like titanium are more difficult to stamp and cause more wear on the tooling in a shorter period of time. There are different tool steel and die coating options that exist that can slow die wear when stronger materials are required, but that increases the overall cost of the parts being produced.

   Material Properties, Thickness, and Part Quality Concerns

   The composition and physical properties of the material selected to produce your metal stamped components play a part in determining the difficulty of achieving highly repeatable quality control standards. While harder and stronger materials add wear to the die, they take well to the metal stamping forming process through a wide range of material thickness producing less QC issues. Softer more flexible and malleable materials perform well at greater thickness, but can shear or fail more easily while forming certain features of the component. Thin walled components made from softer materials will tend to have more challenging QC processes required, driving up the cost of your metal stamped parts. Work with the Design For Manufacturability (DFM) team closely when working with very thin materials. They can help you identify alternatives or die design approaches to overcome the difficulties this requirement produces.

   Material Sheet Size and Coil Width

   Your metal stamping supplier can help select the appropriate sheet metal size or coil width to best produce your part. The geometry and features of your part will dictate the amount of material necessary to produce the end result, but your supplier can design the best orientation for the metal stamping process to save you the most money. The percentage of scrap produced per run creates additional cost per part with no benefit. Reducing scrap saves you money and does not affect the performance of your parts. This is a good way to keep your overall costs down.

   Material Cost and Availability

   As we saw through 2020 and 2021 material cost and availability can be impacted by much more than the standard supply volume being outrun by a sharp increase in demand. Tariffs, shipping challenges, scarcity of 3PL services, mill closures, geopolitical discourse, and global pandemics can all affect the cost of your material pricing and in turn your per part price. Widely used materials like 6061 Aluminum are the most likely to be available at the best price during the most difficult of times and challenging situations. Materials with other valuable properties like high conductivity can be harder to get due to the multi-use end case for the raw material. Titanium and other exotic metals will always be on the more expensive end of the material cost spectrum and have a high likelihood to be harder to find when external factors impact your supply chain.

   Be sure to understand all of your material options when moving your parts to a high volume metal stamping process – it is a big part of the answer to the question “How Much Does Metal Stamping Cost?”. What may have worked well at low volume should be reassessed, evaluated, and either confirmed to have the same material requirements or an alternative can be identified to save you money.

8. Metal Stamping Quality Assurance: What You Need to Know

   September 28, 2022 9:22 am Leave a Comment

   Quality assurance (QA) testing refers to the process of ensuring that a product is of the highest possible quality. The success of metal stamping and fabrication companies heavily depends on the level and degree of quality testing they provide, as the components they produce are often used in critical settings like automotive, aerospace, or medical applications.

   At Manor Tool, we have built a reputation for providing unparalleled custom metal stamping and fabrication services to critical industries. We recognize the importance of quality assurance in metal stamping and metal fabrication, so we have a comprehensive, in-house quality assurance department and QA equipment.

   Here you’ll learn more about how QA works in metal stamping and the types of QA equipment.

   How Quality Assurance Works in Metal Stamping

   ISO 9001:2015 section 3.6.2 defines quality as the extent to which an object’s set of inbuilt properties fulfills requirements. Quality control helps prevent defects when manufacturing metal parts. It also ensures the formed parts meet design specifications and work properly. A well-planned quality assurance program ensures time and cost efficiency in manufacturing while also preventing product safety issues that can lead to additional costs due to product recalls.

   Pre-Fabrication Inspections

   The first step during the pre-fabrication process is to inspect the raw materials. They should have the properties necessary to meet the specification of the parts.

   Then follows a failure mode and effects analysis (FMEA). This systemic evaluation establishes where and how the fabrication process may fail and assesses the relative effect of different failures to identify the parts of the process that require adjustments.

   Advanced product quality planning (APQP) also comes during pre-fabrication inspection. It involves creating a framework of manufacturing procedures and techniques that are satisfactory to the client.

   Fabrication Process Controls

   This phase involves monitoring and documenting fabrication in real time. It also involves confirming whether the process conforms to various quality standards, including:

   • Pressure Equipment Directive (PED)
   • Restriction of Hazardous Substances (RoHS)
   • ISO 9001:2015
   • International Traffic in Arms Regulations (ITAR)
   • Military Specifications (Mil-Spec)
   • Internal quality policies

   Post-Fabrication Confirmation & Testing

   A quality assurance program is only complete if it involves inspections throughout the manufacturing process. Complex and precise quality assurance measuring systems such as 3D scanning finish off the inspection process.

   Quality Metal Stamping Testing Technology

   Here are the most commonly used types of quality assurance equipment.

   Statistical Process Control Systems

   These systems track manufacturing processes by measuring and controlling quality. They trigger various instruments and machines to give quality data, which helps control the manufacturing process.

   Optical Vision Systems

   Optical vision systems provide precise measurements of stampings. An example is our 2-axis optical comparator, which inspects and measures the dimensions of small turned and round parts.

   Functional Gauges and Custom Gauges

   Functional gauges allow immediate checks on parts output to ensure they are fit for assembly and function. The gauge prevents the creation of bad parts and reduces or eliminates non-value-added measurements. On the other hand, custom gauges help develop design and quality standards for metal stamped parts.

   Digital Measuring Machines with Metrology Software

   Digital measurement machines are crucial in quality assurance as they help improve accuracy, increase efficiency, and control what you measure. The metrology software interacts with optical gaging products (OGP) to control, monitor, display, and report every aspect of the measuring process.

   CMM Measurement and Layout Capability

   A coordinate measuring machine (CMM) helps get dimensional measurements of physical objects by detecting discrete points on the surface of the object. An example is our Brown & Sharpe CMM, a popular series that ensures high-speed, accurate measurements.

   Reverse Engineering CAD Software

   Reverse engineering CAD software can create a 3D CAD model from a physical part. Capturing millions of data points at a time, the computer-aided program ensures precise measurements of even the most complex products.

   Quality Assurance Metal Stamping at Manor Tool

   Our quality engineers and inspectors at Manor Tool collaborate with our tooling and development engineers to ensure quality metal stamping services with every project. Manor Tool uses the following QA equipment:

   • Sherr-Tumico Fully Programmable CNC 2 Axis Optical Comparator
   • Brown & Sharpe Digit-Hite Plus
   • Tesa Micro-Hite
   • Micro-Vu Excel S12

   Our ISO 9001:2015 certification is a testament to our commitment to offering quality metal stamping services and products. We also have a certification from Perry Johnson Registrars, Inc. and maintain our processes according to the standard requirements.

   Contact us or request a quote for your project today.

9. Types of Metal Stamping Services: Deep Drawn Stamping & Progressive Die Stamping

   April 1, 2022 1:47 pm Leave a Comment

   Metal stamping is a type of manufacturing process used to transform sheet metal into specific shapes. Many types of metal stamping processes exist depending on the needs of each application, including deep drawn stamping and progressive die stamping. In this post, we’ll provide a breakdown of how deep drawn stamping and progressive die stamping work, along with when to use them.

   The Deep Drawn Stamping Process

   

   Custom Deep Drawn Stamping of Steel Terminal Box Cover

   Deep drawn stamping forms various types of hollow axisymmetric components out of metal sheets. The name “deep drawn” comes from the fact that the end products typically feature depths that exceed their diameter. Most of the shapes that this process forms feature a cylindrical shape, but it’s also possible to form box-shaped products through deep drawn stamping. A wide variety of applications use this process to form many types of products, including baking pans, auto parts, casings, sinks, and plumbing fixtures.

   The process starts with the placement of the metal sheet on the system’s forming die. A blank holder then applies compressive force to the sheet to hold it in place. At this point, a punching tool applies an axial force to the metal, which causes it to deform and draw into the die cavity to form the final shape.

   This process offers a number of benefits, such as:

   • Increased speed due to the ability to simultaneously perform draws in multiple stations
   • Reduced tooling costs
   • Maintained tolerances and high repeatability
   • Durable rolled metal parts featuring a cohesive and elongated grain structure
   • The ability to work with a wide range of metals, including stainless steel, copper, aluminum, and more

   The Progressive Die Stamping Process

   Progressive die stamping involves several workstations that perform different operations on the same part. The part is carried by a stock strip through each workstation until it is completed.

   The process begins when operators place the die into a stamping press. The die then opens as the stamping press moves upward. The die closes as the stamping press moves back down. Metal travels through the die at certain increments as the press makes each stroke. In the process, the stamping die modifies metal by either bending, cutting, shaving, lancing, coining, drawing, or embossing the workpiece.

   Once the die closes, it performs the necessary operation on the metal to form one or more parts. These parts may be either connected to a carrier strip or separate from one another.

   

   Progressive Die Stamping of a Mounting Bracket for a Security System

   The progressive die stamping process comes with several key benefits, including

   • The ability to produce components at a rapid pace
   • The capacity to run multiple cutting or forming operations simultaneously
   • High press tonnage
   • Fast set-up
   • The ability to produce multiple parts per press stroke
   • Maintained control over part location during the stamping process
   • Maintained tolerances

   Choose Deep Drawn Stamping & Progressive Die Stamping Services at Manor Tool

   Depending on an application’s unique requirements, either deep drawn stamping or progressive die stamping may serve as the ideal solution. Both of these processes come with their respective benefits, making them compatible with many manufacturing setups to produce high-quality metal components. Learn more about the drivers that determine how much metal stamping will cost for your high volume production project.

   If you need either of these metal stamping services for your application, the experts at Manor Tool have the experience, knowledge, and resources required to form nearly any type of part. Our deep drawn and progressive die metal stamping capabilities allow us to deliver quality parts and components for a range of industries, including medical, aerospace, automotive, and more.

   To learn more about our services and capabilities, contact us today or request a quote to get started.