Category Archive: Advantages of Metal Stamping

Saving Money on Your Metal Stamped Parts – The Mental

In part one, of this two-part blog series, we began to explore the different ways that manufacturers can cut costs on their metal stamping projects.

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The last post focused on the physical changes that can be made to projects which, when implemented properly, can have a positive effect on your profit margins.

There are additional ways that money can be saved on your stamping projects, beyond changing physical things like the materials used for the part and the tooling used to create it.

In this post, we’ll explore the “mental” and engineering aspects that can lend themselves to a cheaper (and often times more effective) metal stamped part. 

Project Management

Whether you are an engineer or a procurement manager, “project management” is likely not the first item on your priority list when choosing a service provider.  Costs, experience, and expected (promised) timelines are usually the determining factors in your final decision. In reality though, it’s the company’s project management structure and the project managers themselves that directly affect those factors and the ultimate success of your project.

If your service provider cannot immediately lay out who your points of contacts are, and who will be running each step of your project’s timeline, you should reconsider your partnership with this provider.  It needs to be guaranteed that you will have a clear and open means of communication throughout the project, so that if and when changes need to be made (design, materials, delivery, etc.) they can be handled quickly, efficiently, and most importantly, cheaply. Without that line of communication, you run the risk of having to manage the project from afar – costing you both time and money in the long run.

Project management can make or break your metal stamping project. Excellent project management will ensure that every aspect of your project runs smoothly and efficiently, and in a world where time is quite literally money, one cannot afford to run into missed deadlines or incorrectly run parts due to poor project management.

Design Review

When bringing a project to a metal stamper, it’s important to know that the staff is properly equipped (and prepared) to do a design review of your part before accepting the job and bringing it to production.

Design reviews are typically done by the management team and head engineers, and are used to ensure:

  • That the part you require can actually be completed by the machinery on-hand.
  • That your part design is as efficient as possible.
  • That all Tolerances, Dimensions and Radi are suitable for a Metal Stamped Production.

The design reviews provide you with the opportunity to get feedback from individuals that are seeing the project for the first time. The fresh perspective can often lead to suggestions or changes to a part design that can lead to cost savings during part production and an overall better part.

Learn More

For even more ideas on how to save money on your metal stamping projects, download our full resource below:

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Saving Money on Your Metal Stamped Parts – The Physical

In the realm of manufacturing, as with any business venture, keeping costs low is always a top priority for any project. When clients come to us with prints or parts, one of the major concerns that they have is whether or not they are getting the most cost effective outcome.

In this two-part blog series, “Saving Money on Your Metal Stamped Parts”, we’ll cover some of the major ways that money can be saved on metal stamping projects. For the first installment, we’ll cover some of the physical changes you can make to bring costs down.

Materials

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The metal chosen for your stamping project plays a considerable role in the overall costs. It is possible that the material you are planning to use (or have been using) may not be the most cost-effective metal for your part.

It is important to interface with your metal stamping provider to review the potential material options (or alternatives) for the project. Each metal type offers different advantages in terms of formability, machinability, and tensile strength; your stamping provider should be able to determine the pro/cons of each type for your particular project, and present the most economical option.

Some metals, such as aluminum or magnesium, have a tendency to carry higher upfront costs. But they can prove to be the more cost effective option when considering the longevity of your parts.  In other scenarios, the cheaper metal may be the best solution; it all depends on the project requirements.

One of the most common swaps that we see are swaps within the steel family. Manor Tool has often been able to introduce High-Strength, Low-Alloy steel into a job due to the fact that it possesses high corrosion resistance and similar material properties to spring steel, while being offered at lower cost.

When bringing your print to your metal stamping provider, make sure to note:

  • Any changes in part requirements
  • Any areas that are not set in stone, to allow for potential design modifications.

Tooling

Another aspect to consider when working with your metal stamping provider is the tooling requirements of your part. Small changes to your tooling can have a huge impact on both costs and production time.

Manor Tool encourages you to find a stamper that has the capability to provide a finite element analysis. A major portion of the finite element analysis is the determination of whether or not different tooling or additional tooling would make a significant impact on your overall part costs down the line.

In a realm where time is money, the Finite Element Analysis also helps you save money by reducing the timeline of your tooling design cycle. The virtual design simulations can be run in a few hours, meaning you are freed from the machine shop/manufacturing schedules that hard-copy tests are tied to.

Volume

It’s important to keep an eye on the increase of production volume. As production of your metal stamped parts increases, there may be a time where the job transitions from being a “low volume” or “short run” job to being a “high volume” production.   Having a high volume production run opens up the opportunity to revisit your original prototype, and rework the design for cost saving opportinities.

It’s hugely important to find a metal stamping provider that has the capability to take a job from prototype to production, as they will inherently have the ability to help reduce your costs in-house.  As an example, Manor Tool has the internal ability to build hard tooling/progressive dies. As quantities increase from the short run (low volume) process, those progressive dies can bring down the piece-part price significantly, with the investment in a nominal hard tooling cost. 

Be sure to check back soon for the second installment of “Saving Money on Your Metal Stamped Parts”. The next blog will focus on some of “The Mental” adjustments you can make to save money on your parts.

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In the meantime, please feel free to download our full resource on your money saving options:

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Download Your Ebook Now

Would You Like to Cut Down on Metal Stamping Costs?

There are many facets of your company to consider when you want to cut costs. One way to go is to schedule a meeting with one of our skilled design and manufacturing engineers here at Manor Tool to review your drawings and production plan, and help your company meet low or high volume production requirements. Whether this is your first component or your 1,000,000th, Manor Tool can help you cut costs and save money with a “second set of eyes.”  

Offline Time?

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For example, how often are your current dies taken offline for repair and re-tooling? If your current design requires frequent offline time for die repair, have you been able to determine the features that are causing this down time and the lead time extension? Review your design to determine the possibility of altering these features to simplify the component and eliminate unnecessary wear on your die and tooling. Manor’s engineering staff can aid your team with this issue.   

Tooling?

As far as tooling goes, review your current requirements for your components and determine if there are alterations that can be made to reduce complexity and maintain functionality. Just changing square holes to circular holes drastically simplifies machining and tooling requirements. This will reduce your production time and your overall component cost. What about your design and the number of machines and processes that are required? Can changes be made to utilize the same machinery or process?

Automation Possibilities?

Are there portions of your design that currently require manual intervention? You should probably go over these areas to identify possible automation or elimination. Manual machining operations are costly and time consuming. Anything you can do to reduce this will have an immediate impact on your component cost. Our engineering team can help identify opportunities to automate feature creation for your parts.

Having an expert third party review your design and provide feedback is just one of the tips we at Manor Tool can offer you. If you’re interested in a few more tips, Manor Tool has put together The Cost Saving Guide to Metal Stamped Parts which gives you 23 tips that will help save on your next metal stamping project.

To download the eBook Guide, click the button below, or contact Manor today and let us assist you.

  Looking to cut down on cost?Download our Metal Stamping Cost Savings Guide

Manor is Punching Up Production with Acquisition of Turret Press

Manor’s metal stamping and deep draw services encompass a wide range of metals. And since we offer custom tooling and fabricating services for such a diverse array of customers, all in need of specific requirements, we are always on the lookout for the latest machinery to help us serve customers’ needs the best way possible.  In modern, flexible manufacturing, jobs vary, and so should machine tools.

November’s blog mentioned “Freddy” – our robotic work cell that has proven to drastically reduce cycle times for a number of clients. It’s certainly been an innovative use of automation for metal stamping at Manor. Now we’ve added a high-tech press to our arsenal of equipment: a new turret press from Finn-Power, the twenty-year pioneer in hydraulic turret punch presses.

Our new C5 Express Press is a unique combination of reliability, versatility and high performance, as well as ease of operation and maintenance. As a lower cost option for initial low-volume, development volume, or prototyping, the new press offers customers the ability to develop parts before investing in hard tooling for large volume runs.

Manor’s new Finn-Power C5 Express features an auto loader, robotic pick up sheets and loads, and remote programming, all designed to increase production time. Fully networked, the machine allows engineers to develop processes from drawings, using sophisticated NC Express Cam software that generates the G-code for tool paths that are sent to the machine for manufacturing.

The new press adds full networking capabilities, faster processes, lower noise levels, more energy efficiency, and a safer operation. The Finn-Power C5 Express features 20 main tool stations and three multi-tool stations, utilizing one station with 24 tools up to ½” in diameter, and two 6-tool stations with up to ¾” diameter. The result is 53 total tool stations, and a maximum punch diameter of 3.5”.

Additional features include multiple tool-holder sizes that can be switched from station to station, the option for additional index stations, multiple shaping capabilities, multiple job runs from one setup, and an automatic built-in scrap conveyor for fast scrap removal. The machine also offers fast loading and unloading with a smaller footprint.

Manor notes that this new press will allow for immediate tool availability in a short amount of time. The new press, along with Manor’s relationship with suppliers, allows them to have tools delivered to clients within two days.

Two days:  That’s good news for company and clients alike. 

Learn how tools like our new Turret Press allow us to help customers reduce the cost of Metal Stamped parts in our eBook:

Looking to cut down on cost?Download our Metal Stamping Cost Savings Guide

Top 7 Advantages of Progressive Die Metal Stamping Your Parts

Your designers are working hard on your next stamped part and you need to identify the best process.  Should you use
progressive die stamping, cellular work station stamping, or
deep drawn stamping?

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  1. SPEED, SPEED, SPEED! – Progressive die metal stamping is based on the continuous feed of material through the different die stations of a tool.  The nature of the process allows you to create more parts in a shorter period of time when compared with traditional fabrication or machining.  For high volume parts, progressive stamping provides the lowest cycle times per part.
  2. Less Scrap MaterialProgressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal to produce your desired end part shape. The vast majority of material is used, hence, less scrap is produced. Progressive Die Metal Stamping may provide the most cost effective material option for manufacturing your parts.
  3. Quicker Setup – When compared to traditional fabrication or machining, the setup time may be much less for the progressive stamping process. What is achieved in multiple Setups and processes during traditional fabrication and machining, may be performed in one operation if Progressive Die Stamping is utilized. This reduction in Setup and processing will result in a more cost effective piece part.
  4. Create More Geometries with a Single Process – Progressive Die Metal Stamping allows you to create parts with many geometries within a single tool. This video shows a single part progressing through a die. All required geometries of the part are achieved in one Progressive Die operation.
  5. Longer Runs – The continuous material feed used in the progressive die stamping process allows for long runs.   Longer runs between material changes and tooling adjustments mean your parts can be produced in a much shorter time.
  6. High Repeatability – The hard tooling die designs allow for high volume runs without die degradation.  This means that part quality remains high and there are fewer failed parts.
  7. Lower Cost per Part – All of the factors above contribute to reducing the overall cost of your part.  Using progressive die stamping allows you to create robust parts in the most cost effective and expeditious manner.  We look forward to helping you save money on your next project!

 

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