Tag Archive: metal stamping

  1. Could Metal Stamping Create a Real Iron Man Suit?

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    Since Iron Man first appeared in Marvel Comics in 1963, comic book fans and engineers alike have wondered at the feasibility of an exoskeleton that could enhance human strength and abilities. Iron Man’s popularity has soared since the character was introduced into the Marvel Cinematic Universe in 2008, and many fans have constructed their own Iron Man costumes with varying degrees of functionality. But what about the real thing?

    The military has a long history of experimenting with fiction-inspired technologies, and the Iron Man suit didn’t escape their notice. The Pentagon’s Tactical Assault Light Operator Suit (TALOS) program was casually referred to in defense circles as the “Iron Man Suit” until the TALOS initiative shut down in 2019. The commercial sector has also pursued the development of powered mechanical suits, tracing back to General Electric’s failed Hardiman Suit program in the late 1960s.

    As technologies like robotics, artificial intelligence, and wearable solutions continue to advance, efforts to build a real-life Iron Man suit will undoubtedly begin to show more promise. As they do, metal stamping will undoubtedly play a critical role in producing electronics and structural components used in Iron Man suits.

    how to build a real man iron man suit

    A Real-Life Iron Man Suit

    A real-life Iron Man suit will require significant advances in the area of powered exoskeletons. A powered exoskeleton can be defined as a wearable machine that uses various electric motors, actuators, hydraulics, pneumatics, or other technologies to enhance the operator’s strength and endurance. Technologies have already emerged that establish a foundation for a future functional Iron Man suit:

    • Rex Bionics created a powered exoskeleton to help patients with neurological disorders and spinal cord injuries with rehabilitation exercises.
    • ReWalk robotics developed a wearable robotic exoskeleton that restores hip and knee mobility for people with spinal cord injuries.
    • Ekso Bionics has released a series of industrial exoskeleton products to help reduce injuries and improve lifting and material handling capabilities in manufacturing, construction, and other industrial settings.

    Spoiler alert if you haven’t seen 2016’s Captain America: Civil War, but it’s worth noting that these suits don’t look so different from a fictional powered exoskeleton built by Tony Stark for his best friend, Colonel James Rhodes. After Rhodes incurred an injury that paralyzed him from the waist down, Tony Stark designed an exoskeleton that allowed him to walk again.

    Materials for an Iron Man Suit

    In the Iron Man movie, the original suit is built from old missile parts, which would contain the iron alloys that gave the suit its name. The second iteration of the suit used a chromed titanium-steel alloy that couldn’t handle atmospheric flight and caused the suit to nearly crash. Stark’s Mark III suit employs a titanium-gold alloy for its armor components.

    Building a working Iron Man suit here in the real world will require the use of strong and lightweight materials—some which may not even exist yet. It’s worth noting, however, that Marvel may not have been too far off base with titanium-gold alloy. Research at Rice University created a titanium-gold alloy for use in artificial joints that is four times harder than steel.

    Essentially, a real-world Iron Man suit will require a mix of materials that offer strength, durability, performance, and low weight. Other viable material options for some suit components may include aluminum alloys, fiberglass, carbon fiber, or carbon nanotube.

    industrial metal stamping services

    How Metal Stamping Could Contribute to Manufacturing Iron Man Suits

    Medieval suits of armor were crafted by skilled blacksmiths using forging and forming techniques that would evolve into modern metal fabrication methods. While ancient metal fabricators relied on manual forging, cutting, and bending to create armor pieces, modern powered exoskeleton armor could leverage advanced metal stamping to achieve many of the same goals.

    Metal stamping encompasses a variety of processes used to turn flat sheet metal into intricate design shapes. A metal stamping press offers a variety of capabilities, including bending, blanking, coining, deep drawing, punching, piercing, and much more. Many demanding industries already rely on metal stamping to create an expansive range of high-performance parts and components, including:


    Aerospace manufacturers prefer metal stamping for its ability to create reliable parts and components from difficult high-performance sheet metals like titanium, aluminum alloys, and galvanized steel.


    Automotive OEMs turn to metal stampers to create structural components, chassis elements, and mechanical parts used in vehicles.


    Metal stamping produces critical electronics components used in robotics, Internet of Things solutions, smart technology, wearable technology, and virtual/augmented reality solutions.

    Military and Defense

    Metal stamping has long provided essential components for military and defense equipment, including brackets, bushings, clips, connectors, housings, EMI shielding, and much more.Given the demonstrated capabilities of this technology, it stands to reason that metal stamping will have a critical role to play in the production of powered exoskeletons at some point in the near future.

    metal stamping projects

    Waiting for the Avengers to Assemble at Manor Tool

    While metal stamping sees broad use across numerous industries, it seems that Stark Industries may not have an urgent need to incorporate the process into manufacturing its Iron Man suits. However, the metal stamping sector stands ready to answer the call and fabricate essential parts and components to be used within the suits when the time comes.

    In the meantime, Manor Tool provides advanced metal stamping and deep drawing capabilities for numerous industries. For more information, please view our portfolio of services, or feel free to contact us or request a quote today.










  2. Our Latest eBook: The Importance of Metal Stamping in Today’s World

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    Beginning operations in 1959, Manor Tool & Manufacturing Company has since grown and established itself as a premier metal stamping company offering forming, bending, punching, and deep drawn stamping capabilities. Armed with over 60 years of experience, highly skilled team members, and a broad selection of manufacturing equipment, we have what it takes to manufacture high-quality stampings for customers across a wide range of industries.

    Providing Metal Stamping Services to Key Industries Since 1959

    Metal stamping is a simple—but highly versatile—fabrication process. By choosing the right material, stamping press, and tool and die combination, manufacturers can create stamped components and assemblies for virtually any industry and industrial application. Some of the key industries that rely on the procedure for their parts and products include:

    • Aerospace. The metal stamping process allows aerospace manufacturers to maintain a high level of control at each stage of the process, enabling them to ensure the finished component fully meets the application’s requirements and the industry’s stringent standards and safety regulations.
    • Original Equipment Manufacturing (OEM). Metal stampings offer high strength at a low cost, making them ideal for the production of durable and reliable equipment.
    • Construction. Metal stampings demonstrate high strength and wear resistance, both of which are critical for hardware and other components used in harsh construction applications.
    • Medical. In the medical industry, patient health hinges on the quality of the medical devices and equipment. The metal stamping process allows medical manufacturers to produce parts and assemblies that are precise, accurate, durable, and reliable.
    • Commercial and Residential Appliances. Metal stampings are found in a wide range of commercial and residential appliances, from freezers and ice machines to microwaves and ovens to garbage disposals.
    • Electrical and Power. Many electrical components, from simple clips and connectors to highly complex and detailed assemblies, are made in stamping operations.

    Recent Trends in Reshoring and the Effect on Metal Stamping Operations

    Throughout the years, reshoring has served as a common topic of discussion among manufacturing professionals. However, in response to the interruption of global supply chains caused by the COVID-19 pandemic, many manufacturers—including metal stamping companies—have begun taking the steps to move their operations to domestic sites and source their materials from domestic suppliers. While some companies see reshoring simply as a solution to production disruptions and delays, it also offers many benefits outside of a global health crisis.

    Download Our Latest eBook Today!

    For more information about the important role the metal stamping process plays in today’s world, including the industries that rely on it, the benefits it offers, and the impact of the COVID-19 pandemic, download our eBook, “The Importance of Metal Stamping in Today’s World.”

    The Importance of Metal Stamping in Today's World



  3. Deep Drawn Stamping Services at Manor Tool

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    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.


  4. 4 Metals Most Commonly Used in Metal Stamping

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    Metal stamping is a manufacturing process used to form flat sheets of metal into a variety of designs. Sheets of metal are placed in a stamping press where a die or a series of dies cut, shape, or form the material into the desired shape. Metal stamping is done in a variety of ways depending on the required specifications of the final product. Stamping may use a single process with one or more dies, a group of progressive dies in the same machine, or the workpiece may have separate operations performed on different machines, a process known as transfer stamping.

    Manor Tool & Manufacturing is a leading custom component and metal stamping manufacturer for a variety of major industries, including construction, electronics, and solar and wind energy. Here, we share the four most common metals we use in metal stamping and the benefits they offer.

    Four Metals Most Commonly Used in Metal Stamping


    Aluminum is a non-ferrous metal that has a relatively low cost, an excellent strength to weight ratio, and is suitable for high-speed production. Its strength-to-weight ratio enables the production of components that are durable and strong, yet lightweight.

    Aluminum also offers good thermal and electrical conductivity while resisting damage that may be caused by electrical charges or heat. It has the added benefit of not requiring a coating during the finishing process, although it can be anodized to enhance its appearance and improve its corrosion resistance.

    Stainless Steel

    Stainless steel is a ferrous metal that contains high levels of chromium, molybdenum, and nickel. The addition of these elements gives stainless steel greater resistance to corrosion than other types of steel. This metal is available in many different varieties, each with unique characteristics to fulfill specific applications.

    Stainless steel is highly durable, has high tensile strength, and retains its strength and characteristics even when exposed to temperature extremes. Stainless steel is stronger and harder than carbon steel, which makes it ideal for knives or cutting tools, and its stain resistance makes it easy to clean and maintain.

    Carbon Steel

    Carbon steel materials are available in both flat sheets and coils. The metal’s composition differs from stainless steel because it contains 2.1% carbon by weight and has lower ductility and offers less resistance to corrosion. Carbon steel provides several benefits for metal stamping, including being a low cost, high strength material. Carbon steel can also be soldered, and with proper maintenance is a very durable metal.

    Copper & Brass

    Copper is easily formed, making it perfect for fast production of one-piece seamless components, and is compatible with cold forming processes, which hardens the metal. Copper is a low maintenance durable metal that resists corrosion and has natural hygienic properties, which make it suitable for applications in the medical and food and beverage industries.

    Brass is a copper-zinc alloy that retains many of copper’s beneficial characteristics. Brass has a smooth surface, is resistant to corrosion, easily soldered, and offers conductivity that makes it suitable for a wide range of electronic applications.

    Download our eBook!

    To learn more about the types of metals we use in metal stamping and how our team will fill your manufacturing needs, contact us today or download our eBook!