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.
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:
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.
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.
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.
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.
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
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.
At Manor Tool, our custom tooling die capabilities include single and multi-station progressive dies ranging from 48 to 96 inches with a 400-ton press capacity. For more than 60 years, we’ve been offering precision metal stamping services to our clients in a range of industries, including aerospace, medical, oil and gas, agriculture, telecommunications, and more.
Our extensive capabilities and experience allow us to match specific types of tooling dies to the requirements for your project.
Types of Tooling Dies for Metal Stamping
A stamping die is the tool that forms a blank sheet of metal into a desired shape. There are different types of dies for cutting and forming, and the ones we work with depend on the needs of the project:
Blanking Dies: Blanking is an accurate way to create flat, uniform pieces. It cuts your metal shape in one simple operation.
Coining Dies: Coining is an ideal choice for pieces that require different features on each side—like coins, sporting medals, badges, buttons, and more. The die and punch squeeze the metal within a confined area to leave the die’s features on one side and the punch’s features on the other.
Compound Dies: To cut both inner and outer features in one stroke, manufacturers use compound dies. The inner punch is in the lower die set, while the perforators are in the upper die.
Forming Dies: These dies compress or pull the plastic or sheet metal over a formed surface to create the desired metal shape. There are a variety of forming processes, including bending, flanging, drawing, and stretching, among others.
Piercing Dies: Similar to blanking dies, piercing dies are used to make holes in sheet metal.
Progressive Dies: With these dies, you can perform multiple operations at the same station with a minimal number of punches. It’s an efficient process that’s used to make electronics, automobile components, and a variety of other complex parts.
Draw Dies: Drawing dies are used to make cup- or box-shaped items by pushing the shape into the metal, then holding the metal in place to prevent wrinkling. Everything from oil filters to baking pans are made via drawing.
Features of Tool & Dies
Dies are made from special steel that can withstand the demands of daily operation. Steel for through hardening (material grade 1.2379) offers good dimensional stability after hardening and a working hardness of about 60-62 HRC. Another standard option is high-speed steel (material grade 1.3343), which, with a working hardness of about 63-65 HRC, offers greater wear resistance and hardness when compared to steel for through hardening. Both are used for medium-strength strip material (up to 400 N/mm² for steel for through hardening and up to 500 N/mm² for high-speed steel).
Not all dies are created equal. There are a few characteristics that will help you identify a high-quality die:
Consistent Outcomes: No matter how complex the piece, the die should consistently produce a precise result.
Minimal Variations Per Design: Watch for flaws like guidance pins that are too small or missing pressure pads.
Easy to Turn Design into Production: Each new die for the same project/operation should match previous dies. The design should be able to be translated into real life again and again without variation.
At Manor Tool, high quality, precision, and customer satisfaction are our priorities. With our custom tooling, you’ll enjoy guided, in-press removable, and inserted cutting details, high-speed metals, and sensor automation to ensure each part, no matter how complex, is perfect for your application.
We work with alloy steels, carbon steel, stainless steel, aluminum, brass, copper, plastics, and a variety of composites to achieve your desired results. As a custom tool and die company, we’ve made countless components throughout the years, ranging from simple to highly complex, prototypes to high-volume production. We understand and stay compliant with a number of industry standards, including ISO, ITAR, Mil-Spec, and RoHS. To learn more about metal stamping and our wide range of services, contact us or sign up for our newsletter. When you’re ready to start your project, request a quote—we can’t wait to work with you.
Manor Tool & Manufacturing Company is a premier metal stamping specializing in punching, bending, forming, and deep drawn stampings. One of our core service offerings is progressive die stamping, a manufacturing process that involves running the workpiece through multiple stations, each of which performs different operations, to achieve the desired component. Equipped with over 60 years of metal stamping experience, highly skilled employees, and a broad selection of manufacturing equipment, we can produce stampings in low quantities for prototyping purposes or high quantities for full production purposes.
Below, we highlight how parts and products are made using the progressive die stamping process.
Overview of the Progressive Die Stamping Process
Progressive die stamping is a metal forming process used to create components for a wide range of industries, from appliances and automobiles to medical devices and plumbing supplies. It is commonly used for high-volume production projects since the progressive dies are built to handle higher speeds.
The equipment setup used for the process consists of multiple individual workstations, all of which perform one or more operations on the workpiece. The component is carried from station to station by the stock strip on which it is formed. At the final workstation, the fully formed piece is cut from the strip.
The steps in a typical progressive die stamping operation are as follows:
The progressive die is placed in the proper position within the stamping press, which ensures it opens when the press moves up and closes when the press moves down.
The metal strip is fed into the stamping die with each press stroke, forming the piece and/or removing any excess material.
The automated feed moves the metal strip forward to the next station, where the next operation(s) is/are performed.
The stamped piece is removed from the metal strip at the final workstation.
Contact Manor Tool for Die Stamping Needs
Looking for a partner for your next progressive die stamping project? Turn to the experts at Manor Tool! Our highly advanced stamping presses with automatic servo material feeders and arbors enable us to work a range of materials up to 35 inches wide, 96 inches long, and 0.005–0.500 thick to tolerances of ±0.0005 inches. Our custom die tooling capabilities allow us to accommodate nearly any component request for one-off or long-term production operations since we can design, maintain, and inventory custom dies for customers.
We are the ideal partner for any stamping project. Our experience and equipment give us everything we need to produce quality parts and products with minimal error rates, which is why our customers come to us time and again for their stamping needs.
Want additional information on our progressive die stamping capabilities? Connect with us on LinkedIn or check out some of our past projects:
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.
During the tooling development phase, third-party tooling providers often take ownership of a variety of time-consuming, laborious, or specialized tasks, including:
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:
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
☐ Tool installation
☐ Spare parts list
☐High-risk of repair parts
☐ Spare parts inventory
☐ Spare parts supplier information
☐ Contact info
☐ Purchasing history
☐ Complete records
☐ Project management
☐ Tool service
☐ 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
☐ 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.
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:
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:
Fire extinguisher housings
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
Design modification flexibility
Consistent part quality at the lowest price possible
Stocking programs and inventory management for metal stamping volume purchases
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.
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
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.
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.
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:
Blank holder pressure
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.
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:
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.
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!
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.
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
Fewer physical prototypes
Shorter design cycle
Reduced design cycle costs
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.