How Are Parts Made Using Progressive Die Stamping?

Progressive die stamping is a highly efficient manufacturing process used to create complex metal parts with high precision and consistency. It involves feeding a continuous strip of metal through a series of stations within a progressive die, where each station performs a specific operation—such as cutting, bending, or forming—to gradually shape the material into the final part. This method allows for mass production at high speeds while maintaining tight tolerances, making it ideal for industries that require durable, repeatable components.

Understanding the Progressive Die Stamping Process

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

1. A progressive die is carefully positioned in a stamping press to ensure smooth opening and closing during operation.
2. Strip metal is fed through the die, and each press stroke performs precise actions such as blanking, punching, and forming. Some dies are designed to automatically remove excess material, increasing automation and efficiency.
3. The metal strip is then advanced to the next station, where additional operations are performed progressively to build up the desired shape.
4. At the final station, the completed part is separated from the strip and prepared for further processing or assembly.

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How Parts Are Made Using Progressive Die Stamping

This process ensures ultra-high precision at every stage, making it suitable for critical applications across various industries. Let’s take a closer look at the key steps involved in creating these high-quality parts.

Stock Strip Layout & Design

The process begins with designing the stock strip using advanced computational modeling. Engineers optimize the layout of punches, bends, and holes to ensure accuracy and efficiency in the final product.

Tool Steel and Die Set Machining

Once the design is complete, CNC machining is used to produce the die blocks with exact specifications. These parts undergo rigorous quality checks before being used in production to ensure consistent performance.

Secondary Processing: Grinding & Heat Treating

Parts are strengthened through heat treatment, which increases their hardness and dimensional stability. Grinding may also be applied to achieve even higher levels of accuracy and surface finish.

Wire EDM

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

Die Assembly

All die components are assembled according to the original design using precision instruments to ensure proper function and durability.

Stamping the Parts

The die is installed in a stamping press, and the metal strip is fed through, undergoing multiple operations per press stroke until the part is fully formed.

Packaging and Shipping

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

Industries That Rely on Progressive Die Stamping

Many industries depend on progressive die-stamped parts, including automotive, medical, aerospace, and consumer goods. These parts are essential due to their durability, precision, and ability to be produced in large volumes quickly.

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

ESI has provided innovative solutions for many industries, including:

• Aqua Lung SCUBA Diving Part – We reduced material waste and improved quality, offering a more cost-effective solution for our client.
• Seismic Cable Restraints – We manufactured 20,000 safety-critical restraints in just eight weeks, improving both finish and performance.
• Pre-Plated Cover Plate for Push-Button Lock – We achieved a 0.002-inch tolerance, saving our customer $70,000 annually.

Our Progressive Die Stamping Services

At ESI, we continuously invest in new technologies to improve quality and reduce costs for our customers. With over 30 years of experience in metal stamping and mission-critical parts, we are dedicated to delivering exceptional results. To learn more about how we can help with your tool and die needs, contact us or request a quote.