AMFAS provides a wide-range of stamped metal parts using many stamping methods. We can provide parts made from progressive stamping dies, punch press stampings, single-stage dies, and deep-drawn parts from transfer presses. We can advise the most cost effective process for your application or part.
The simplest method of stamping is to use a single-stage die to “cookie cut” a part from flat metal stock. The die set uses a cutout in the base that represents the part and a punch from above to cut the part shape into the cutout. The metal material is repositioned and the process repeats. Parts fall through the base and are collected. Additional dies may punch out additional holes, or bend the part into various shapes as needed. This method involves siginficant handling of the material and parts, but offers lower tooling costs. It’s intended for lower volume, prototype, or rapid prototyping of parts.
Punch-press stamping is a step up from single stations dies. The punch press may have several die sets where the attendant will move the part from station to station to punch, form, or assemble pieces together. This process involves more tooling, and is intended for a higher volume of parts.
Progressive Die Stamping
Progressive die stamping automatically produces parts once the die is set-up. Metal coils are fed into a progressive stamping die through automized means, while a stamping machine repeatedly stamps then feeds the metal coil into the die set. Progressive dies for small parts can be produced at over 2000 pcs/minute.There is almost no direct labor costs other than the set-up and gathering of the parts as they are produced. Although tooling costs are significant; for high-volume production, this offers the most cost effective production.
Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. This is achieved by redrawing the part through a series of dies. The most common uses for deep drawing is to make containers sucha as aluminum cans. The process uses the cold-working characteristic of most metals, as the metal is stretched, it becomes stronger but more brittle. (This allows us to break a coat hanger wire by repeatedly bending the steel wire back/forth until the steel wire breaks). A metal coil is formed/drawn into the can shape in a series of steps by deforming the metal in incremental steps. As the metal is pushed/formed into the can shape, the metal that was formed becomes stronger but more brittle. This allows the unformed, softer metal to then be pulled/drawn into the can shape without ripping apart. Both cylindrical cans as well as square cans are able to be fabricated this way.
AMFAS has the capability of supplying all stamping needs, from ¼ inch thicknesses or more if needed in all types of metals. We have tooled hundreds of components, and provided millions of parts with the highest level of quality.