Many traditional power press metal stamping companies can perform one only one action: single stroke, short-run stamping.
This process requires one tool for each operation needed to make a finished part — meaning long lead times, high labor costs, and an inability to create intricate or tight-tolerance parts.
Traditionally, fabricating parts that required more than a bend or two was costly and inefficient.
A manufacturer could either repeatedly change the tool on a single press or occupy a number of presses, each performing one action required for a completed part. Even using multiple presses, secondary machining services were often required to truly complete a part.
The Benefits of High Volume Progressive Stamping
With progressive metal stamping, ESI eliminates those hassles and inefficiencies. A progressive stamping tool features a number of stations, each with a unique function.
As strip metal feeds through a progressive stamping press, unrolling steadily from a coil, each station in the tool performs a different cut, punch, or bend.
The actions of each successive station add onto the work of the previous stations, resulting in a completed part.
For very simple parts, progressive die metal stamping may not be the best option. But there are many scenarios in which progressive stamping is ideal. Advantages of progressive stamping include:
- Speed: With a continual feed of material, progressive stamping machines operate at extremely high speeds of hundreds of parts per minute and with minimal downtime.
- Low Labor Cost: One operator can oversee many machines that run unattended due to electronic monitoring embedded in our custom tooling.
- Run Length: The same continual feed of material that provides progressive stamping it’s speed also allows for long production runs. More production time between material changes means more completed parts in shorter amounts of time.
- Minimal Scrap: Scrap metal is inevitable in any manufacturing process, but it is minimized by optimized tool design of progressive stamping.
- Quick Setup: Multiple setups, tool changes, and die changes are required to produce complex parts with conventional short-run stamping methods; only one setup is required to produce completed parts using progressive stamping.
- Complex Geometry: Creation of parts with complex geometries is possible by the building nature of the die stations in a progressive tool.
- High Repeatability: The dies of a progressive stamper are hard tooled. They can withstand the high volume runs of progressive stamping without degrading, maintaining the high quality of the parts produced.
- Low Part Cost: These factors combine to reduce the per part cost of parts manufactured by progressive stamping.