How Are Parts Made Using Progressive Die Stamping?

Progressive die stamping is a highly efficient manufacturing process that involves feeding a strip of metal through a series of workstations, each performing specific actions to shape and form the material into strong, precise components. This method is widely used across various industries due to its ability to produce large volumes of parts quickly and consistently.

Understanding the Progressive Die Stamping Process

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

1. A progressive die is installed in a stamping press, ensuring smooth opening and closing movements during operation.
2. Metal strips are fed through the die, where each press stroke performs precise blanking and forming operations. Some dies automatically remove excess material, enhancing automation and efficiency.
3. The strip advances to the next station, where another process is applied progressively to build up the final design.
4. At the last station, the finished part is separated from the strip for further processing or assembly.

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How Parts Are Created Through Progressive Die Stamping

This process ensures high precision and tight tolerances at every stage, making it ideal for complex and high-volume production needs.

Stock Strip Layout and Design

The process begins with designing the progressive die using advanced computational models. Engineers optimize the placement of punches, bends, and holes on the metal strip to ensure accurate results.

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 parts undergo rigorous quality checks before being used in production.

Secondary Processing: Grinding and Heat Treatment

Parts are strengthened through heat treatment, which increases their hardness and durability. Grinding may also be used to improve surface finish and dimensional accuracy.

Wire EDM

Wire electrical discharge machining (EDM) is used to create intricate shapes with high precision. It can achieve cutting tolerances as tight as ±2 µm and surface finishes as low as Ra 0.1 µm.

Die Assembly

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

Stamping the Parts

The completed die is installed in a stamping press, where the metal strip is processed through multiple stations, gradually forming the final part.

Packaging and Shipping

Once produced, parts are packaged using automated systems to ensure accuracy and efficiency in shipping.

Industries That Rely on Progressive Die Stamping

Many sectors depend on this technique for mass production, including automotive, medical, plumbing, and consumer goods. The durability and speed of progressive dies make them ideal for high-volume manufacturing.

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

At ESI, we have developed critical components for many industries, such as:

• Aqua Lung SCUBA Part — We reduced material waste significantly, improving quality and cost efficiency.
• Seismic Cable Restraints — We delivered 20,000 safety-critical parts in just eight weeks.
• Pre-Plated Cover Plate — We achieved high consistency and saved the client $70,000 annually.

ESI’s Progressive Die Stamping Services

With over 30 years of experience, ESI continues to invest in new technologies to enhance quality and reduce costs. Whether you need custom stamping or die-making services, we’re here to help. Contact us today or request a quote to learn more about how we can support your manufacturing needs.