What Is EV Stamping?
Metal stamping involves using a stamping press and dies to convert flat sheets of metal into the desired shape. Within the automotive industry, metal stamping plays a critical role in the production of electric vehicles (EVs).
The automotive industry relies on metal stamping due to its ability to efficiently create complex components that adhere to tight tolerances and specifications with optimal repeatability. It is particularly well-suited for EV components, as it can produce lightweight parts that decrease carbon emissions and improve fuel economy. Here, we will go over the various EV stamping advantages, different metal stamping techniques, and common EV applications.
Advantages of Using Stamping in the EV Industry
EV metal stamping offers a wide range of advantages, including:
- Cost-effectiveness. Metal stamping dies are robust and affordable to maintain, meaning that once they are designed and built, there are no additional investment costs. This makes it easier to produce parts in high volumes while maintaining quick speeds and competitive prices.
- Minimal material waste. The metal stamping process utilizes as much of the workpiece material as possible, resulting in reduced waste.
- Automation. Metal stamping processes can be easily automated, leading to increased quality and decreased labor costs. Using automation, you can produce large component quantities without making significant investments in labor. Additionally, automation significantly improves precision by reducing the risk of human error.
Efficient Automotive Metal Stamping Processes Utilized
There are numerous highly efficient EV stamping processes to choose from, each of which offers its own set of unique benefits. Common stamping methods include:
Progressive Die Stamping
This technique utilizes a series of stamping stations. It starts by placing the metal workpiece into the stamping press. As the press moves down, the die closes and stamps the metal; as the press moves up, the workpiece progresses to the next station where a different punching, bending, or cutting operation takes place. At the final station, the finished part separates from the rest of the metal.
Because progressive die stamping can accommodate several operations at once, it is ideal for long production runs. It also offers high speeds, which translates to improved efficiency.
Compound Die Stamping
In compound die stamping, compound dies perform a series of operations simultaneously (punches, cuts, etc.). This allows for the creation of finished parts in a single pass, making it a highly cost-effective process, particularly for manufacturing flat components.
Fourslide Machine Stamping
Fourslide stamping, otherwise known as multi-slide stamping, uses four different slides that are aligned horizontally. All four tools are used in quick succession to shape the metal workpiece. This technique offers improved flexibility for design changes and is well-suited for creating complex bends or cuts.
Applications for EVs
Metal stamping is utilized throughout the EV industry to produce reliable and accurate components used in the design, manufacture, and operation of electric vehicles. Common applications include:
- Body-in-white (BIW) stampings
- Brackets
- Bus bars
- Connectors
- Floor panels
- Heat shields
- Interior components
- Power supply components
- Seating structure components
- Terminals
- Under-the-hood components
- And many more
EV Metal Stamping from ESI
Metal stamping is a highly efficient process for producing a wide range of electric vehicle components with optimal speed and accuracy. At ESI, we’re an IATF-certified leader in custom metal stamping services. Using advanced automation equipment, we can deliver EV stampings of the highest quality in volumes ranging from 1,000 to over 20 million. For more information about our automotive metal stamping capabilities, or to get started on your next stamping project, request a quote today.
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