Category Archive: Services

Metal Stamping Transfer Tooling Checklist

Tooling encompasses a sizeable investment in most product manufacturing. Carefully documenting tooling transfer procedures will safeguard production when changing providers due to quality, cost, or logistics issues. Many industries commonly use transfer tooling to take advantage of third-party expertise, including appliances, automotive, aerospace, furniture assemblers, machine shops, medical device manufacturers, sheet metal stampers, and more.transfer tooling ebook

During the tooling development phase, third-party tooling providers often take ownership of a variety of time-consuming, laborious, or specialized tasks, including:

  • Design
  • Machining
  • Heat treating
  • Routing
  • Barcoding
  • Turning
  • Pressing
  • Debugging
  • Final inspection with coordinate measuring machines (CMM)

Manor Tool & Manufacturing Company is a first-class metal stamper with over 60 years of experience. Our team has extensive experience developing and fabricating tooling, and we can also optimize and incorporate transferred tooling into our operation. We work with a variety of metals, such as:

  • Aluminum
  • Cold-rolled steel
  • HSLA
  • Spring steel
  • Stainless steel

We have earned a reputation for high-quality services, excellent customer service, and competitive pricing, prompting many customers to transfer their stamping dies to us from other suppliers. Read more about the strategies for getting the most from your transfer tooling here. 

Checklist for an Effective Transfer Tooling Procedure

Not all tooling transfers are the same. Be as thorough as possible, and be sure to speak with your transfer partnering company about any materials they may need. Additionally, consult with your previous provider about any proprietary info and materials that they must include in the transfer. This checklist will help to ensure nothing gets missed in the transfer between providers. You can download a checklist for your own records by clicking here!

Complete tool drawings

Hard copy

CAD files

Procedures

Tool installation

Debugging

Spare parts list

High-risk of repair parts

Replacement parts

Spare parts inventory

Spare parts supplier information

Contact info

Pricing

Purchasing history

Complete records

Project management

Tool service

Repair

Complete component QC records

May include inspection data

Component-specific inspection fixtures and their drawings

Final sample strip that represents the last material run off the tool

Verify security or attachment of the tool to the shipping crate

Verify that the shipping paperwork is accurate/complete

Tool

Asset #

Customs declarations

Bill of lading

Correct shipping address

Final verification of the following:

Shut height

Die dimensions

Material thickness and width

Die type

Tonnage requirement

Nitro requirement

Air cushion requirement

Special feed requirement

Straightener requirement

Material specifications

Die shape

Remaining cut edge

Special oil requirements for die

Produce Higher Quality Products With Manor Tool

When you invest in tooling to manufacture your products, make sure you have a defined and easily repeatable transfer tooling process in case issues arise with your third-party provider. Manor Tool has implemented efficient transfer tooling procedures, ensuring a fast and easy transition for our customers. We value close partnerships with our clients and welcome existing and prospective customers to tour our facilities at any time.

If you’d like to learn more about transfer tooling, we invite you to download our eBook. For questions on our products or services, please contact us or request a quote today.

 

Short-Run Metal Stamping

Short-run metal stamping is a process used to manufacture small quantities of punched metal parts. A short run can typically be defined as a production run that produces less than 5,000 parts. Short-run stamping has applications across a wide range of industries. If you are looking for faster lead times and quicker delivery, then short-run production may be a good option for you.

Short-run metal stamping can be perfect for low volumes of seasonal products, specialty goods, or other situations where a high permanent tooling investment isn’t feasible. Metal stamping is cost-effective, versatile, quick to set up, and offers precision cuts and shapes.

Short Run Stamping for Parts and Components

Short-run metal stamping offers a cost-effective way to produce high-quality, reliable parts with a faster turn-around time. Short-run production has applications across a wide variety of industries, such as:

  • Automotive
  • Aerospace
  • Commercial lighting
  • Construction
  • Electronics
  • Home appliances
  • Medical

In the short-run metal stamping process, uniform parts are created using metals such as aluminum, brass, copper, steel, and more. Since short-run stamping requires a small amount of material, the cost of production is reduced. Created from a single sheet metal blank, short-run metal stampings feature good density and generate less waste than parts fabricated using multiple pieces of metal. Given the low-volume nature of the process, the lead times will be significantly reduced in comparison with standard stamping runs.

The stamping process involves a piece of metal secured firmly in place by a blank holder. The piece of metal is then repeatedly punched into a series of forming dies. This method of production lends itself well to parts that are symmetrical and have a depth of twice their diameter. Here are some examples of metal-stamped products:

  • Aluminum cans
  • Engine cylinders
  • Fire extinguisher housings
  • Kitchen sinks
  • Muffin pans

Short Run Metal Stamping at Manor Tool

At Manor Tool, we serve a diverse range of customers across industries, including automotive aftermarket parts, medical devices, electrical, pumps and meters, and detention. Our short-run metal stamping capabilities have a versatile range of uses, such as:

  • Prototype metal stamping
  • Metal stamping test runs
  • Small- and medium-volume runs
  • One-off small stamping production runs
  • Metal fabrication
  • Design modification flexibility
  • Consistent part quality at the lowest price possible
  • Stocking programs and inventory management for metal stamping volume purchases

Manor Tool can metal stamp a variety of metals:

  • Aluminum
  • Beryllium copper
  • Brass
  • Carbon steels
  • Copper
  • Phosphor bronze
  • Stainless steel

Why Choose Manor Tool and Manufacturing

Manor Tool and Manufacturing is an ISO 9001:2015-certified company that started in 1959 as a tool and die shop. We are a full-service provider of metal fabrication services, including high-quality custom metal stampings. Over the years, Manor Tool has grown into a first-class metal stamping company and quality is our highest priority. Our engineers follow each step of the process from the start to finish to ensure that every part meets or exceeds customer expectations.

Our specialties include punching, bending, forming, and deep drawn stampings, and we can create precision metal stampings, formed components, assemblies, and sub-assemblies, and more. Our material thickness ranges from 0.005-0.5 inches, depending on the material being used and the part being produced. Whether you need low or high production volumes, we have a process to affordably provide you with the parts you need.

To learn more about our short-run stamping capabilities or any of our other services, please contact us today.

Stamping Simulations for Sheet Metal Forming

While prototype creation is highly beneficial in designing parts and detecting errors before production, it can be time consuming and costly. Metal stamping simulations are an ideal solution, removing the need to produce real products and prototypes to run tests. This process enables engineers to utilize specialized software to simulate the formation of sheet metal. Rather than discover errors in early production runs, stamping simulation makes it possible for engineers to find and eliminate many issues before machining a component.

What Is Sheet Metal Simulation?

Sheet metal simulation is a versatile tool that can benefit a diverse range of industries, including aerospace, automotive, and medical.

By saving suppliers time and money, sheet metal simulation makes it easier to develop and test new products. This technology makes it possible for engineers to detect design errors before production, as well as facilitate the design process, enabling engineers to test how different materials will function and react to one another when the product is machined. Additionally, engineers can take advantage of stamping simulation software to explore different tool design options and more accurately predict which designs are likely to have the highest success.

It is important to note that sheet metal simulation depends on many factors to function properly. The more information the software has, the more accurate its simulations will be. Inputting the desired sheet metal and running through every step in the machining process will enable the simulator to set realistic expectations.

Benefits of Metal Stamping Simulations

Cost Effective

Sheet metal simulation helps manufacturers save money by detecting errors, identifying the most appropriate material, and determining the most efficient and economical machining process for a component. As a result, engineers don’t spend as much designing the part and are less likely to redesign it at a later date.

Additionally, stamping simulation reduces the forming severity of the part and creates less scrap. This ultimately results in cost-savings, as there is less material required to produce the part.

Efficient

Simulation software enables manufacturers to test different materials and detect potential issues before a production run, which means the production run itself is more efficient. Components are less likely to require costly, time consuming redesigns, and there is less of a need to spend time testing dies and materials. Stamping simulation makes it easier to design a part that can be formed more efficiently, cutting down on wasted time.

Low Stress

While prototyping can be stressful and frustrating, metal forming simulation can drastically reduce this by eliminating many of the more expensive, time consuming aspects of the testing and design phase. In fact, metal forming simulations can reduce or fully eliminate the need for prototyping. As there is no need for guesswork during the tryout process, there is a reduced likelihood of unforeseen problems and an overall reduction in the frustration that often accompanies component design.

Higher Component Strength

Certain types of crash simulation software can perform virtual testing to determine the strength of the final product. This, in combination with the ability to test different types of materials before committing to a production run, makes it easier for engineers to make alterations to the part design to create higher amounts of strength as needed.

Access to Detailed Component Information

In addition to its efficiency and cost-effectiveness, metal stamping simulation software provides an immense amount of information about the design. It can indicate structural weaknesses, such as areas where the metal may wrinkle, tear, or buckle. This software also provides information regarding:

  • Part thickness
  • Forming severity
  • Strain distribution
  • Blank holder pressure
  • Springback tendencies

Contact Manor Tool to Learn More About Stamping Simulations

Since our founding in 1959, Manor Tool & Manufacturing has been providing quality metal stamping solutions to clients in a diverse range of industries. We are continually committed to providing our engineers with the most up-to-date technology and training to supply our customers with efficient, reliable solutions, including stamping simulations. To learn more about our capabilities, contact us today.

 

Metal Stamping for the Medical & Healthcare Industries

At Manor Tool & Manufacturing Company, we are an industry-leading metal stamping company specializing in bending, forming, punching, and deep drawn stamping. We accommodate projects involving a variety of metal materials and prototype to production quantities. Equipped with over 60 years of industry experience, we have the knowledge and skills necessary to produce high-quality custom stampings for customers in a wide range of industries, including medical metal stampings.

In the medical and healthcare industries, equipment—including all integrated parts, components, and assemblies—are subject to strict standards that focus on ensuring the safety of medical personnel and patients. Our extensive experience and state-of-the-art stamping facility enable us to meet these standards, thereby producing stamped components suitable for medical devices and instruments.

Below we outline the key considerations we keep in mind during metal stamping operations for medical and healthcare customers, as well as some of the common equipment, materials, and end products involved.

Key Considerations for Medical Metal Stampings

As an experienced metal stamping company, we’re well aware of the push for smaller, lighter, and more economical components in the medical industry. Meeting these demands without sacrificing performance, reliability, and durability necessitates careful planning during the design and manufacturing stages. Some of the measures we take to improve the manufacturability of a metal stamping for medical devices include:

  • Utilizing prototypes. Prototyping is a crucial aspect of component design and development. It allows product designers and developers to test out different design iterations, allowing them to identify potential issues and areas for improvement and, ultimately, decide on the design that best meets customer specifications.
  • Reducing the need for secondary operations. During the design stage, it is important to consider what operations are required to produce the desired product. By simplifying or adjusting the design, it is possible to reduce or eliminate the need for secondary processing (e.g., machining), which reduces the amount of time and labor required during production.
  • Investing in engineering services. Companies with extensive engineering services are likely to have broader knowledge and equipment, both of which can help produce stampings with greater precision and complexity in a shorter period of time.
  • Adhering to quality control (QC) standards. As indicated above, medical and healthcare equipment must meet strict criteria. Quality control operations allow manufacturers to verify the products they produce meet both industry standards and customer specifications.

Equipment Employed for Medical Metal Stampings

During stamping operations, industry professionals may employ a variety of tooling, depending on the part and production requirements. Some of the most widely used for medical stampings are:

  • Soft tooling. Soft tooling refers to tools made from pre-hardened steel or other similar materials used in low-volume manufacturing operations. These tools often come with lower investment costs ($75–$500 for simple parts and up to $2000–$3000 for complex parts) but are generally less durable than hard tooling.
  • Hard tooling. Hard tooling is made from hardened steel and other similar materials to ensure it is durable enough to withstand use in high-volume manufacturing operations. While it has a higher initial investment cost than soft tooling ($5000–$300,000, depending on design complexity, size, and other factors), it often has a lower cost per unit over time.
  • Progressive dies. Progressive die stamping operations employ a series of specialized stations within a tool (generally hard tooling) installed at separate workstations to gradually shape the workpiece. As the workpiece progresses through the tool, new stamped elements are added until, at the end of the operation, it exits the tool as a finished part. This stamping method is ideal for high-volume production runs.

At Manor Tool & Manufacturing Company, we offer in-house tooling capabilities. By leveraging our AutoCAD and/or SOLIDWORKS software (for design operations) and MASTERCAM software (for CNC machining and wire EDM operations), we can produce custom tooling for any precision metal stamping project. For example, our progressive dies can accommodate pressures of 22–400 tons, tolerance requirements of ±0.0005 inches, and material thicknesses ranging from 0.005–0.500 inches. In addition to tooling design and manufacturing services, we can incorporate and/or repair existing tooling.

Common Materials Used

Given the strict design and manufacturing requirements in the medical and healthcare industries, metal stampings are generally made from one of two materials:

  • Stainless steel. This material demonstrates numerous characteristics that make it suitable for use in medical components, such as high strength, corrosion resistance, chemical inertness (including with cleaning compounds), biocompatibility, and durability. For these reasons, among others, medical manufacturers often use it in implantable devices, surgical instruments, and other medical equipment.
  • Aluminum. Similar to stainless steel, this material exhibits excellent strength, corrosion resistance.

Typical Stamped Components for Medical Applications

Industry professionals utilize metal stamping to produce a wide range of precision parts and components for medical and healthcare equipment, such as:

  • Covers for thermometer probes
  • Equipment enclosures and housings
  • Oxygen tank subcomponents
  • Pump components
  • Surgical instruments (e.g., drills, forceps, retractors, etc.)
  • Syringes

Choose Manor Tool for Your Medical and Healthcare Stamping Needs

Metal stamping is a versatile manufacturing process used to produce parts, components, and assemblies for a variety of industries, including the medical and healthcare industries. If you’re looking for a partner for your next medical or healthcare project, the experts at Manor Tool are here to help. We have the experience and equipment to create durable and reliable stampings suitable for use in medical devices and other medical applications.

For more information about our metal stamping capabilities, contact us or request a quote today.

Deep Drawn Stamping Services at Manor Tool

Some of the most intricate steel, aluminum, copper, brass, nickel, and plastic components are created with deep drawn stamping. Even though it’s a highly precise endeavor that requires specific equipment and experience, it’s a simple concept that involves pressing a sheet of metal into a cavity to create the desired shape of the part. The technique gets its name from the fact that the finished product is usually deeper than it is wide. Visit our Deep Drawn Stamping page to view how this process is performed!

deep drawn stamping step 2

At Manor Tool & Manufacturing Company, we work with more than 30 400-ton presses, giving us the capability to produce parts ranging from 0.005 to 0.05 inches in thickness with tight tolerances. We’re committed to quality control and production monitoring to ensure the best products for our customers.

Benefits of Deep Drawn Stamping

There are many advantages, including:

  • High Quality Parts: Since they’re created from a single piece of metal, there are no seams, joints, or weak areas.
  • Strength and Durability: Stamping the metal increases its strength via strain hardening.
  • Cost-Effective Repeatability: The process is especially effective for large runs. Once the dies are created, you can manufacture a high volume of precise components.
  • Versatile:Deep drawn stamping is ideal for even the most complex designs.
  • Short Lead Time: It’s relatively easy to go from design to production.
  • Precise:The tools create accurate cuts and shapes, and since no heat is used in the process, you can avoid warping for greater precision.
  • Reduced Waste: A precise, replicable process means you know how much material you’ll need and you can avoid excess scrap metal.

Working With Manor Tool & Manufacturing Company

What started as a small tool and die shop in 1959 has become an ISO 9001:2015-certified leader in metal stamping. Manor Tool can handle both low-volume prototyping and high-volume production, and thanks to our range of equipment in our 44,000-square-foot facility, we can customize your order based on your unique needs.

We’re committed to innovation and the education of the next generation of manufacturers throughout the Chicago area and all over the United States. Visit our Deep Drawn Stamping service page or Contact us to learn more about deep drawn metal stamping and the other services we offer, or request a quote for your next project.

 

What’s the Difference Between FEA, FES, and CFD in Manufacturing?

Since our inception in 1959, Manor Tool has grown from a small tool and die shop to an industry-leading provider of metal stamping services. We can handle project volumes ranging from single prototypes to high-volume production runs. We manage a variety of stamping operations, including bending, forming, punching, and deep drawn stamping, plus design processes like finite element analysis (FEA).

We understand that the production of high-quality products begins before the production process. We keep talented engineers and inspectors on staff to ensure quality is built into every component from its conception. We follow every part through each step of the manufacturing process, including any outside contractors, to ensure that it will meet and exceed the expectations of our customers. As part of our strict adherence to quality assurance practices, we are ISO 9001:2015-certified and ITAR compliant.

This stringent dedication to quality led us to incorporate Finite Element Analysis (FEA) capabilities into our design processes. This blog post will discuss FEA and related methods and how they apply in manufacturing.

What Is Finite Element Analysis?

The Finite Element Analysis—a numerical method that has become a core element of mechanical engineering and most simulation software programming—gives engineers the tools to simulate application characteristics and see how a design will perform in its intended operating environment. FEA essentially deconstructs a design into thousands of individual nodes, then applies mathematical equations to determine how each node or group of nodes will react to forces such as stress, heat, motion, vibration, and other physical factors.

Until recent years, Finite Element Analysis was traditionally reserved for scientists, PhDs, and specialized engineers in advanced industries due to its complexity. The development of faster computers, advanced software capabilities, and better graphics user interfaces have opened up the FEA process to general manufacturers since FEA no longer requires extensive IT infrastructure to implement during the design phase of a product.

Is Finite Element Simulation the Same as Finite Element Analysis?

FEA is simply the application of the Finite Element Simulation in academia, the term FES is usually preferred. Since manufacturing deals with real-world applications of FEM principles, FEA is more commonly used. While not precisely interchangeable, both terms refer to the same set of concepts.

Finite Element Analysis vs. Computational Fluid Dynamics

Computational Fluid Dynamics (CFD) combines principles from physics and mathematics to predict how a liquid or gas will move, as well as how the material will impact other components within a system. CFD is commonly applied in aerodynamics to model airflow and predict how it will impact the functionality of air and ground vehicles. It is also used to predict the behavior of fluids within process systems.

While these two processes may seem similar, CFD and FEA are typically used in different predictive modeling scenarios:

  • Finite Element Analysis is primarily applied to determine structural problems, electromagnetic issues, and heat transfer concerns. FEA relies on a set of equations determined by the application of principles laid forth in the Finite Element Method.
  • Computational Fluid Dynamics provides a similar outcome, but for fluid flow problems. Instead of using FEM, CFD relies on equations determined by the Finite Volume Method (FVM) and the Finite Difference Method (FDM).

It’s worth mentioning that FEA and CFD have some overlap. For certain scenarios, these two methodologies may simply be different roads to the same destination. CFD can be applied to structural problems and FEA can be applied to fluid flows, though the results in each case may be less accurate. As such, the situations mentioned above are how these predictive processes are most commonly applied to ensure the utmost accuracy in advance of physical production.

FEA at Manor Tool & Manufacturing

At Manor Tool & Manufacturing, we’ve been honing our FEA capabilities for more than ten years. FEA gives our designers the capability to look into the future and gauge the viability of designs before we spend time and money creating physical prototypes. Manor has used FEA or simulation of metal forming to determine whether a proposed design will produce parts free of fracturing and / or wrinkling, etc. Every project we have run with FEA has been successful on the first try.

Some of the key benefits offered by our FEA services include:

  • Superior design accuracy
  • Better design insight
  • Virtual prototyping
  • Fewer physical prototypes
  • Shorter design cycle
  • Reduced design cycle costs
  • Higher productivity
  • Improved ROI

For more information about our FEA capabilities and how they can help save time and money on your design, please contact us or request a quote.

The Keys to Successful Die Maintenance

Founded in 1959, Manor Tool & Manufacturing started as a small tool and die shop. Since then, we have grown into a first-class metal stamping company that specializes in employing bending, forming, punching, and deep drawn stamping methods for prototype to high-volume production runs. Equipped with 32 presses, our team uses new and existing tooling—e.g., dies—to fulfill customer orders, which of course requires proper die maintenance.

Ensuring that each stamping we deliver meets both the quantity and quality our customers demand, necessitates the use of well-maintained, high-quality dies. The following blog post outlines what to look for in a quality die and how best to maintain it for successful operations.

What to Look for in a Quality Die

When initially choosing a standard die or designing a custom one, there are three key characteristics to look for:

  • A well-designed die should facilitate achieving a consistent outcome. This may include having highly specified details and discrete components that cannot be placed incorrectly after repair and maintenance operations.
  • Die builds should yield only a small number of variations per die design. Examples of flaws to look out for include too small guidance pins and bushings and missing pressure pads.
  • A die design should be easy to translate to die production without having to worry whether the one produced matches previous ones.

Having and maintaining these three qualities in the dies employed for a stamping operation is essential to operational success. In particular, high-quality maintenance programs that use predictive systems and preventative maintenance help resolve potential problems before they significantly affect production.

Die Maintenance Methods

Die maintenance can involve several different operations, such as:

Sharpening

The cutting sections and punch edges of a die wear down over time through normal use, resulting in potential errors in the parts produced. Periodically employing a grinding wheel to sharpen the dies prevents these conditions from impacting manufacturing operations. Furthermore, careful sharpening practices insure the quality of the die steels.

Shimming

Adding shims to die sections may be necessary to ensure each die station maintains the proper timing. When adding shims, some of the things to keep in mind include:

  • Avoiding improper shim placement and the use of multiple shims shims
  • Use the correct number of shims
  • Ensuring proper clearance for all fastening elements
  • Removing debris and burrs from all shims

Cleaning and Inspection

Regular cleaning and inspection of dies provide industry professionals with opportunities to detect and prevent issues that may evolve to full-blown production problems. Some of the things to look for include:

  • Loose fasteners
  • Missing or broken components
  • Worn/degraded parts or parts in need of refinishing
  • Insufficient lubrication
  • Excessive debris and buildup
  • Fits, allowances, and clearances of die components

Die Maintenance Steps for Engineers, Floor Managers, Etc.

When performing general inspection and maintenance, industry professionals—including engineers and floor managers—may check the following components and practices:

  • Documentation for quick repairs
  • Dies for black grease, slivers, and sludge
  • Last strips for burrs, punch shear/brake lines, slivers, and tool marks
  • Slugs for proper penetration/tightness and variance
  • Die shoe guideposts for galling, tracking, and wear
  • Pilots for presence and length
  • Punch lengths for height
  • Punch floats and pumps for configuration and condition
  • Die inserts and forms for height & timing with other related details
  • Strip lifters for height & timing with other related details
  • Toe straps and clamps for condition
  • Die sections for chips and side galling
  • Stripper faces for wear
  • In-die stock pushers for performance
  • Preventative and predictive maintenance procedures; continuous improvement practices

In addition to inspecting these die and equipment parts, there may be other items to check on indicated in the die maintenance card instructions. Once the inspector finishes checking all the parts necessary, they should fill out the die maintenance card with all the work performed and file it away, tag the tool inspected, and order any replacement parts needed.

Partnering with Manor Tool & Manufacturing Company

With 60 years of experience in metal stamping and hard tooling, Manor Tool & Manufacturing Company has the skills and knowledge necessary to produce parts that meet the specifications outlined by customers. By employing regular in-house die maintenance and part inspection, we ensure the highest level of quality and process reliability, plus quick response time. For more information on how to maintain a die or our manufacturing capabilities, contact us today.

 

A Step-by-Step Guide to Our Deep Drawn Stamping Process

Since 1959, Manor Tool & Manufacturing Company has been fabricating metal components for a range of industries, including aerospace, automotive, medical, energy, and consumer goods. With a specialty in high-quality metal stamping, Manor Tool can create anything from a one-off prototype to a high-volume run requiring progressive tooling.

Manor Tool’s deep drawn metal stamping services include standard cylindrical and axisymmetric shapes as well as box-shaped items. We can make modifications to meet each customer’s unique needs, such as coining, curling, extruding, and embossing. Our shop is also ISO 9001:2015 certified for quality, and our process has been established to produce finished parts to tight tolerances that meet or exceed customer specifications.

The Process of Deep Draw Stamping

The deep draw process is necessary for parts with a depth that exceeds their diameter, like beverage cans, deep pans, assembly housings, and other containers. A blank piece of sheet metal is positioned over a die, and a punch is used to force the metal into the die and create a custom shape. Once the die is made and tooling set, the process is relatively inexpensive, especially for high-volume production, because it can be completed with minimal downtime or maintenance.

From start to finish, the deep draw stamping process is as follows:

  1. Engineers provide a design.
  2. Our Engineers review the design and determine whether the part can be created with Manor’s fleet of more than 30 400-ton presses.
  3. We consider the ideal thickness, shape, and radii of the finished part and what will work best based on customer specifications and our expertise. Typical parts we create are between 0.005 and 0.5 inches, with extremely tight tolerances. We can also make dies up to four feet wide and eight feet long.
  4. We implement Finite Element Analysis, or FEA. This allows us to virtually create the part using the final design and accurately simulate the entire manufacturing process. Any problems with design or tooling can be easily discovered and changed before it costs time and money.
  5. Based on material requirements, we select the right flat metal sheet. Options include aluminum, brass, copper, and steel.
  6. As part of set up, Engineers note the depth of the part and the degree of radius. They position the die and punch properly on the press. The metal sheet, or blank, is placed on the die.
  7. The punch is applied against the die with force, which shapes the workpiece as desired. This process is repeated to produce the correct depth and size.

The finished part, having been created from a single sheet of metal, is strong and seamless. The precision of the process allows it to be completed quickly, for less technical labor costs and quicker turnaround times.

What Can Be Made From Deep Draw Stamping Metal?

Metal stamping is widely used to manufacture a wide range of parts, and deep draw stamping produces parts with depth greater than the diameter. Commonly produced items from the deep draw stamping process include panels, tanks, containers, sinks, automotive parts and pots or pans for kitchen use.

Some types of parts or items are more likely to be produced via deep draw metal stamping:

· Parts that must be produced at high volume. Deep draw stamping works quickly and efficiently once it has been set up, making it ideal for longer runs.

· Parts that must be water- or gas-tight. The one-sheet process is seamless.

· Parts that must be produced to tight tolerances. Metal stamping has high accuracy and can be set to tolerances as low as ±.0005 in.

· Parts that have complex, axisymmetric shapes. The die and punch create these geometries more quickly and accurately than many machining processes.

· Parts for which cutting or welding would be undesirable from a durability or aesthetic standpoint.

Quality Metal Stamping at Manor Tool

Deep draw metal stamping is an ideal process for cylindrical or axisymmetric parts that can be manufactured quickly to tight tolerances. While anything from a prototype to a small run to high-volume manufacturing can be completed using deep draw metal stamping, it is most cost efficient for large production runs. Once the tooling is set, the process runs quickly and with little required oversight.

Manor Tool’s ISO 9001:2015 certified quality control processes at every stage of production ensure that a high quality finished part fits all specifications. Not only can our pre-production process identify inefficiencies before work begins, but we can assist in determining the ideal shape, thickness and materials to use for best results.

To learn more about our deep draw stamping services or to get started on a project, contact us today or request a quote.

Applications and Tips for Transferring Tooling

Developing effective transfer tooling procedures lets small and medium-sized manufacturers minimize their tool development costs and hedge against unpredictable component suppliers. Tooling is an expensive process, but it typically involves only a one-time cost, so anything that can make the tooling process more affordable will greatly impact your overall expense portfolio. As the trade war between the U.S. and China continues to heat up, it’s now more important than ever to consider transferring tooling back to American manufacturers to mitigate increased costs and other supply chain disruptions as a result of tariffs.

External suppliers perform a number of time-intensive processes during tooling development so that you don’t have to. Third-party tooling services include:

  • Machining
  • Heat treating
  • Routing
  • Barcoding
  • Turning assembly
  • Pressing
  • Debugging
  • CMM final inspection

When you let other manufacturers perform these tasks, you can dedicate more time and resources to applications more central to your company’s mission.

In this post, we describe eight transfer tooling strategies that will enable you to get the most from outsourcing your tooling production.

Eight Steps to Successfully Transfer Your Tooling

Following these tips will help you execute a successful tooling transfer.

1.) Make Sure Everything’s Covered in Your Contract

All parties subject to the transfer tooling agreement must sign nondisclosure agreements to ensure that any new innovations remain between those concerned. NDAs must cover part prints, quality assurance policies, and production requirements. Additionally, governmental and third-party regulators often require legally sound contractual agreements to be signed before work can begin.

2.) Create a Strong Partnership that Emphasizes Communication

A partnership based on trust and open communication between the businesses will ensure that parts arrive on time and that nothing is lost in translation. Both companies must be willing to take the appropriate steps to ensure that communication channels remain open throughout the process.

3) Perform On-Site Assessments Early and Often

It’s important to have a solid understanding of your transfer partner’s capabilities before entering an agreement. Additionally, once production has begun, frequent and respectful on-site assessments will ensure that you have as much information as possible on the status of your tooling.

4) Agree on a Clear Production Schedule

Create a detailed transfer schedule using data from on-site assessments. The schedule must include transfer dates for all parts and tools while allowing enough time to produce the tools to your standards.

5) Build Enough Safety Stock to Allow Efficient Tooling Transfer

The supplier must provide enough safety stock that you can use during the validation of production equipment and processes at the new facility. Typically, business partners set up a six-week timeframe within the transfer schedule, although it’s important to allow for the possibility of additional shifts and/or weekend work to make sure everything’s running on time.

6) Ensure You Buy the Correct Consigned Equipment

The third party may need to buy nonconsigned equipment to successfully build your transfer parts. Consignment equipment typically includes tooling and spares, fixtures, inspection gauges, and all other product-specific equipment.

7) Validate All Transfer Tools Before Ending Your Contract

When the third-party’s transfer tools leave production, you should ensure that they’re all compatible with your existing facility. Many companies validate transfer tooling by analyzing their new parts’ similarity to existing parts and performing golden sample processes.

8) Design Production Molding For Use in the Next Transfer

Once the tools have been validated and incorporated into your production processes, make sure you or your contractor save the production mold to simplify the transfer tooling process next time you go through it.

Applications for Transfer Tooling

Just about any industrial manufacturer needs to develop effective transfer tooling procedures. A wide range of manufacturers regularly contract third parties to ensure that their next generation of tools is of as high quality as possible. Industries that implement comprehensive transfer tooling procedures include:

  • Sheet metal stampers
  • OEMs
  • Appliance manufacturers
  • Automotive and aerospace OEMs
  • Furniture assemblers
  • Machine tool shops
  • Medical device manufacturers

Transfer tooling can work with a wide range of metal products, such as:

  • Aluminum
  • Cold-rolled steel
  • Spring steel
  • Stainless steel
  • HSLA

Manor Tool: A Trusted Source for Transfer Tooling

Manor Tool & Manufacturing is an ISO 9001:2015–certified company that can help you with all your transfer tooling requirements. If you’re looking for more best practices on how to implement the most effective transfer tooling procedures, download our free eBook, “Everything You Need to Know About Transferring Tooling.”

If you’re looking to embark on a transfer tooling procedure of your own, feel free to contact us at your earliest convenience to request a free quote.

Download Our Transferring Tooling eBook >>