Jun. 23, 2025
Hardware
Metal stamping is a manufacturing process used to convert flat metal sheets into specific shapes. It is a complex process that can include a number of metal forming techniques — blanking, punching, bending and piercing, to name a few.
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There are thousands of companies across the U.S. that offer metal stamping services to deliver components for industries in automotive, aerospace, medical, and other markets. As global markets evolve, there is an escalated need for quickly-produced large quantities of complex parts.
Metal stamping is a fast and cost-effective solution for this large-quantity manufacturing need. Manufacturers who need metal parts stamped for a project generally look for three important qualities:
The following guide illustrates best practices and formulas commonly employed in the metal stamping design process and includes tips to incorporate cost cutting considerations into parts.
Stamping — also called pressing — involves placing flat sheet metal, in either coil or blank form, into a stamping press. In the press, a tool and die surface form the metal into the desired shape. Punching, blanking, bending, coining, embossing, and flanging are all stamping techniques used to shape the metal.
Before the material can be formed, stamping professionals must design the tooling via CAD/CAM engineering technology. These designs must be as precise as possible to ensure each punch and bend maintains proper clearance and, therefore, optimal part quality. A single tool 3D model can contain hundreds of parts, so the design process is often quite complex and time-consuming.
Once the tool’s design is established, a manufacturer can use a variety of machining, grinding, wire EDM and other manufacturing services to complete its production.
Metal stamping is a fast and cost-effective solution for this large-quantity manufacturing need. Manufacturers who need metal parts stamped for a project generally look for three important qualities:
There are three major types of metal stamping techniques: progressive, fourslide and deep draw.
Progressive die stamping features a number of stations, each with a unique function.
First, strip metal is feds through a progressive stamping press. The strip unrolls steadily from a coil and into the die press, where each station in the tool then 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.
A manufacturer might have to 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. For that reason, progressive die stamping is the ideal solution for metal parts with complex geometry to meet:
Fourslide, or multi-slide, involves horizontal alignment and four different slides; in other words, four tools are used simultaneously to shape the workpiece. This process allows for intricate cuts and complex bends to develop even the most complex parts.
Fourslide metal stamping can offer several advantages over traditional press stamping that make it an ideal choice for many applications. Some of these advantages include:
As its name implies, a fourslide has four slides — meaning that up to four different tools, one per slide, can be used to achieve multiple bends simultaneously. As material feeds into a fourslide, it is bent in quick succession by each shaft that is equipped with a tool.
Deep drawing involves pulling a sheet metal blank into the die via a punch, forming it into a shape. The method is referred to as “deep drawing” when the depth of the drawn part exceeds its diameter. This type of forming is ideal for creating components that need several series of diameters and is a cost-effective alternative to turning processes, which typically require using up more raw materials. Common applications and products made from deep drawing include:
Short run metal stamping requires minimal upfront tooling expenses and can be an ideal solution for prototypes or small projects. After the blank is created, manufacturers use a combination of custom tooling components and die inserts to bend, punch or drill the part. The custom forming operations and smaller run size can result in a higher per-piece charge, but the absence of tooling costs can make short run more cost-efficient for many projects, especially those requiring fast turnaround.
Let’s take a look at how this initial tool is created: Stock Strip Layout & Design: A designer uses is used to design the strip and determine dimensions, tolerances, feed direction, scrap minimization and more.
Tool Steel and Die Set Machining: CNC ensures a higher level of precision and repeatability for even the most complex dies. Equipment like 5-axis CNC mills and wire EDM machines can cut through hardened tool steels with extremely tight tolerances.
Secondary Processing: Heat treating is applied to metal parts to enhance their strength and make them more durable for their application. Grinding is used to finish parts requiring high surface quality and dimension accuracy.
Wire EDM: Wire electrical discharge machining shapes metal materials with an electrically-charged strand of brass wire. Wire EDM can cut the most intricate shapes, including small angles and contours.
Metal stamping is a complex process that can include a number of metal forming processes —blanking, punching, bending, and piercing and more. Blanking: This process is about cutting the rough outline or shape of the product. This stage is about minimizing and avoiding burrs, which can drive up the cost of your part and extend lead time. The step is where you determine hole diameter, geometry/taper, the spacing between edge-to-hole and insert the first piercing.
Bending: When you are designing the bends into your stamped metal part, it is important to allow for enough material — make sure to design your part and its blank so that there is enough material to perform the bend. Some important factors to remember:
Coining: This action is when the edges of a stamped metal part are struck to flatten or break the burr; this can create a much smoother edge in the coined area of the part geometry; this can also add additional strength to localized areas of the part and this can be utilized to avoid secondary process like deburring and grinding. Some important factors to remember:
Bend Distortion/Bulge: The bulging caused by bend distortion can be as large as ½ the material thickness. As material thickness increases and bend radius decreases the distortion/bulge becomes more severe. Carrying Web and “Mismatch” Cut: This is when a very slight cut-in or bump-out on the part is required and is typically about .005” deep. This feature is not necessary when utilizing compound or transfer type tooling but is required when utilizing progressive die tooling.
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Custom metal stamping describes metal forming processes that require custom tooling and techniques to produce parts specified by the customer. A wide range of industries and applications employ custom stamping processes to meet high-volume production needs and ensure all parts meet exact specifications.
Design engineers can work on a wide range of metal stamping projects for clients across various industries. To better illustrate the versatility of custom stamped metal parts, we’ve outlined a few recent projects completed by ESI’s engineers below.
A client in the medical industry approached ESI to custom metal stamp a part that would be used as a spring and electronics shield for vital monitoring equipment in the medical field.
ESI was able to meet the complex design requirements using a material stacking technique that allowed us to cut many part blanks at once, limiting costs and reducing lead times.
In another instance, we were asked to redesign an existing electrical connector cover; the client, AFC Cable Systems, was looking for a higher-quality product at a lower price with shorter lead times.
This allowed for significant cost savings — 80% off the cost of a 500,000-part order — as well as a lead time of four weeks rather than 10.
Related links:For more information, please visit Metal stamping Service.
An automotive client required a high-strength, pressure-resistant metal grommet for use in Ford Transit Vans airbags.
The ESI team built a 24-station progressive tool to ensure proper development of the draw and used DDQ steel with zinc plating to ensure optimal strength and corrosion resistance. Metal stamping can be used to create complex parts for a huge range of industries. Curious to learn more about the various custom metal stamping applications we’ve worked on? Visit our Case Studies page, or reach out to the ESI team directly to discuss your unique needs with an expert.
We could not be happier about being a customer of ESI for the past 10 years. They are extremely professional, provide excellent quality, and best of all, make working with them fun.
Len OdegaardI would recommend ESI for future stamped parts (sheet metal parts) in the future. The Gemini shields don’t seem particularly easy to make, and, as you know, we had a difficult time finding a suitable vendor. The quality of work has been great and the dimensional accuracy outstanding. I find them very easy to work with and very accomodating for development. The pricing is fair and it’s nice to work with a local outfit.
Roy AbramsNational Material Company is regarded as a global leader in servicing the needs of the steel industry and leading industrial and consumer product manufacturers. With over 50 years of expertise in metals processing and supply chain management, NMC offers metal stamping services as a part of a wide array of steel processing capabilities. Read on to learn more about metal stamping:
Metal stamping is an incredibly versatile and efficient manufacturing process that takes flat metal sheets or coils and transforms them into precisely shaped and intricate parts. By utilizing force, pressure, and specialized tooling, components with diverse forms — including bends, curves, cutouts, and embossing, are possible. This process offers low costs and higher lead times — both for short and long production runs while keeping consistent quality, dimensional accuracy, and repeatability of the manufactured parts.
At the core of metal stamping lies the stamp press, a component responsible for applying the necessary force and pressure to mold the metal sheets or coils into the desired shape or profiles. This powerful machine incorporates specialized tooling known as dies, which performs a variety of stamping operations on the metal. By carefully controlling the movement of the press and the interaction between the dies and the metal in the production line, the stamping process brings forth remarkable transformations in the shape and structure of the material.
Now, let’s dive deeper into the fascinating world of metal stamping and explore its different stages and intricacies.
Based on the requirements of the part, specialists select metal sheets or coils. Considerations include mechanical properties such as strength and ductility, as well as other factors like corrosion resistance, conductivity, and cost. The selected material should be compatible with the stamping process and the desired part’s functionality.
The selected materials undergo preparation processes like cutting, slitting, and leveling to obtain the proper dimensions and flatness necessary for stamping. The prepared metal sheets or coils are then fed into the stamping press, where an automated feeding mechanism ensures precise positioning for accurate stamping.
As the stamp press initiates its action, the dies close together, subjecting the metal to high force and pressure. This pressure deforms the material, shaping it according to the contours of the dies. There are also a variety of metal-forming processes that may be involved in stamping. These include blanking (cutting out the desired shape), bending (creating angles or curves), coining (adding fine details), and punching (making holes or cutouts), which these experts perform sequentially or simultaneously, depending on the part design.
Throughout the stamping process, operators implement quality control measures, including real-time monitoring and inspections. They ensure that the parts meet the specified tolerances and quality standards.
After stamping, these professionals may apply additional post-processing steps, such as deburring (removing sharp edges), cleaning, surface treatment, and coating, to enhance the appearance, durability, and functionality of the stamped parts.
By following this systematic approach, the stamping process transforms raw metal sheets or coils into precisely shaped components that serve diverse industries and applications. It is an exciting blend of precision engineering, material science, and advanced manufacturing techniques that continue to revolutionize the way we produce complex metal parts.
a high-volume production process that utilizes a series of dies arranged in a progressive manner. The metal sheet or coil is continuously fed through the dies, and each station performs a specific operation, such as cutting, bending, or forming. It allows for the creation of complex parts with multiple features in a single pass.
Similar to progressive stamping, but instead of the metal sheet moving continuously through the dies, mechanical systems transfer the sheet from one station to another. Companies use this method often for larger and more complex parts that may require additional operations or precise positioning.
Also known as multi-slide stamping, this is a specialized technique that uses a four-slide machine to form intricate shapes or perform multiple bending and forming operations simultaneously. Operations commonly use multi-slide stamping for small, complex parts with multiple bends or curves.
A stamping process used to create cylindrical or box-shaped parts with significant depth. A specialist will place a blank over a die and which is then forced into the die cavity using a punch. As the metal undergoes plastic deformation, it takes the shape of the die cavity, resulting in a deep-drawn component.
A precision stamping process used to produce high-quality, burr-free parts. It involves the use of a specialized fine blanking die that incorporates three distinct cutting edges. When components that require exceptional flatness, dimensional accuracy, and edge quality, specialists will often use fine blanking.
These are some of the primary types of stamping processes. Each type has its own advantages and applications, and manufacturers select the most appropriate method based on factors such as the complexity of the part, required production volume, and desired quality.
Metal stamping finds widespread applications across various industries due to its versatility and ability to produce high-quality, precisely shaped, and unique components.
It plays a vital role in the automotive manufacturing industry — producing components such as body panels, brackets, chassis parts, engine mounts, brackets, and suspension components. The process ensures the production of lightweight, durable, and structurally sound parts that meet stringent safety and performance requirements.
Metal stamping also reached the heavens through the aerospace sector. Key components like aircraft structural parts, engine parts, brackets, and fittings can be fabricated with the process which ensures the production of lightweight parts with complex geometries while maintaining strength and durability, contributing to enhanced fuel efficiency and performance.
In the electronics industry, electronic devices (connectors, terminals, heat sinks, shielding components, and brackets) are widely used. Metal stamping made it possible for the precise fabrication of intricate parts required for electronic assemblies while ensuring proper electrical conductivity and durability.
The process is also employed extensively in the manufacturing of household appliances like refrigerators, washing machines, ovens, and HVAC systems. It produces components such as panels, enclosures, brackets, and handles, providing both aesthetic appeal and structural integrity.
In the medical field, devices such as surgical instruments, orthopedic implants, brackets, and connectors also have components that have undergone the metal stamping process ensuring the production of precise, sterile, and biocompatible parts critical for medical applications.
And how can we forget the construction industry, where metal stamping products are present in structural and decorative components like brackets, connectors, fasteners, hinges, and cladding panels — to name a few? Overall, the process allows the creation of durable, corrosion-resistant parts that meet the demanding requirements of the industry.
Metal stamping is an intricate process that demands the expertise and proficiency of a company well-versed in the field. When your industry requires the best metal stamping products and services, National Material Company (NMC) is the obvious choice. Renowned as a leading metal processor, NMC excels at providing exceptional solutions to meet your exact standards.
NMC offers a diverse range of capabilities, including metal stamping, by leveraging technological breakthroughs and innovations developed over years of compelling research and development. We’ve worked with diverse industries and delivered superior products and services across the globe, and in working with us, we guarantee…
ISO Certified Quality System
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