How Are Parts Made Using Progressive Die Stamping?

Progressive die stamping is a highly efficient manufacturing process used to produce complex, durable metal parts in high volumes. This method involves feeding a continuous strip of metal through a series of workstations, each performing specific operations such as cutting, bending, and forming. The result is a precise, repeatable part that meets strict quality standards.

Understanding the Progressive Die Stamping Process

The progressive die stamping process typically consists of four main stages:

1. First, the progressive die is installed into a stamping press, ensuring it can open and close properly during operation.
2. Next, the metal strip is fed through the die, where each press stroke performs necessary actions like blanking and forming. Some dies are designed to automatically remove excess material, enhancing efficiency.
3. The strip then advances to the next station, where additional processes are applied progressively to achieve the desired design.
4. Finally, at the last station, the finished part is separated from the strip for further processing or assembly.

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How Parts Are Made with Precision

Every stage of the progressive die stamping process is designed to meet ultra-high tolerance standards. Let’s take a closer look at the key steps involved in creating these precision parts:

Stock Strip Layout & Design

The process begins with the design of the progressive die using advanced computational models. Engineers optimize the layout of punches, bends, and holes to ensure the final product meets all specifications.

Tool Steel and Die Set Machining

Once the design is complete, CNC machining is used to create the die blocks according to exact specifications. These components are rigorously tested to ensure accuracy and reliability before mass production begins.

Secondary Processing: Grinding & Heat Treating

To enhance strength and stability, parts undergo heat treatment, which increases their hardness and dimensional accuracy. Grinding may also be used to improve surface finish and precision.

Wire EDM

Using an electrically charged brass wire, die blocks are shaped with extreme precision. Wire EDM allows for intricate cuts and contours with tolerances as tight as ±2 µm and surface finishes as smooth as Ra 0.1 µm.

Die Assembly

After all components are machined, the die is assembled by skilled engineers who use precision tools to ensure it matches the original design specifications exactly.

Stamping the Parts

The completed die is installed in a stamping press. As the metal strip passes through, each operation adds to the previous one, shaping the part precisely until it's fully formed.

Packaging and Shipping

Once the parts are produced, they are packaged using automated systems to ensure accuracy in counts and weights, making shipping faster and more efficient.

Industries That Rely on Progressive Die Stamping

Progressive die stamping is widely used across many industries, including automotive, medical, appliance, and plumbing. It enables high-volume production with consistent quality and cost-effectiveness due to the durability of the dies and the speed of the process.

Explore More: Progressive vs. Fourslide vs. Traditional Power Press Stamping

At ESI, we’ve developed critical components for various industries, such as:

• Aqua Lung SCUBA diving parts — We reduced material waste significantly, improving quality and lowering costs for our client.
• Seismic cable restraints — We delivered 20,000 safety-critical parts in just eight weeks with improved finish and performance.
• Pre-plated cover plates — We achieved tight tolerances, saving our customer $70,000 annually.

ESI’s Progressive Die Stamping Services

With over 30 years of experience in metal stamping, assembly, and mission-critical parts, ESI continues to invest in new technologies to improve quality and reduce costs for our clients. Whether you need a custom die or a large-scale production run, we’re here to help. Contact us today or request a quote to learn more about how we can support your tool and die-making needs.