Compound Die Stamping Services
Frigate’s Compound Die Stamping delivers precision with a single press stroke. Our advanced tooling ensures high repeatability and tight tolerances for complex parts.Â
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Advantages of Compound Die Stamping Services
Reduced Setup Time
Compound die stamping requires minimal changeovers between parts, leading to faster production cycles and improved workflow efficiency.
Lower Tooling Costs
Integrating multiple operations into a single die reduces tooling expenses, making it cost-effective for long-term production.
Improved Part Strength
The stamping process compresses and shapes the material, enhancing the final component's structural integrity and mechanical properties.
Compatibility with Diverse Metals
Compound die stamping suits various materials, including stainless steel, aluminum, and brass, accommodating diverse manufacturing needs.
Custom Compound Die Stamping Services for Precise Manufacturing
Custom Compound Die Stamping integrates multiple forming operations into a single press stroke, enhancing efficiency and dimensional accuracy. This advanced technique minimizes material waste and setup time, allowing for rapid and consistent production of complex components. The process is adaptable to various metals, including stainless steel, aluminum, and brass, meeting specific industrial standards and tolerances. Custom-designed tooling ensures optimal part integrity, achieving high repeatability and uniform quality across large production runs. This approach streamlines manufacturing and provides a cost-effective solution for precise, high-volume projects.Â
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Our Compound Die Stamping Process
A continuous metal strip, often in coil form, feeds into the compound die press, ensuring a steady supply for the operation.Â
The metal strip is precisely aligned in the die using guide pins and stops, ensuring accurate positioning for each press stroke.Â
The press activates, performing multiple operations—cutting, bending, and forming—in a single stroke, streamlining the fabrication process.Â
The compound die executes cutting and shaping tasks simultaneously, creating intricate features efficiently in one step.Â
After the stroke, the completed part is ejected from the die ready for inspection or further processing, if necessary.Â
The process repeats with minimal interruption, maintaining consistent quality and high production rates for large volumes of parts.Â
Compound Die Stamping Materials
The compound die stamping process requires careful consideration of design and tooling. Precision in these areas ensures efficient production and high-quality part formation.Â
Austenitic Stainless Steel (300 Series) offers excellent corrosion resistance and formability, making it ideal for complex shapes in harsh environments. Its high chromium and nickel content provides superior durability and maintains strength even at elevated temperatures, making it suitable for medical, food processing, and chemical industry components.Â
Due to heat treatment, this material is known for its high hardness and strength. It is chosen for parts that demand wear resistance and impact strength, like cutting tools and automotive gears. It maintains dimensional stability under stress, making it suitable for precision manufacturing.Â
A popular choice for aerospace and transportation, this tempered aluminum alloy delivers a strong yet lightweight solution with excellent machinability. It combines good corrosion resistance with high tensile strength, supporting intricate designs while reducing overall component weight.Â
With a high copper content (70%), cartridge brass offers superb flexibility and strength, ideal for deep drawing and detailed forming. Its high malleability makes it perfect for manufacturing intricate connectors, precision terminals, and hardware components.Â
With a purity level of 99.99% copper, OFHC copper exhibits unparalleled electrical conductivity. This makes it suitable for critical electrical components, precision electronics, and RF applications, where slight impurities can affect performance.Â
Known for its high strength and flexibility combination, DP steel is favored in automotive applications to meet safety standards while reducing vehicle weight. It exhibits excellent energy absorption and formability, perfect for complex automotive panels and safety components.Â
Alloys like 2024 and 7075 offer exceptional strength and toughness. They are typically used in aerospace applications where performance under stress is crucial. These materials undergo heat treatment to increase strength, making them suitable for precision stamped parts that withstand extreme forces.Â
Phosphor bronze, with added phosphorus for increased hardness and wear resistance, is chosen for electrical springs, connectors, and bearings. It resists fatigue and corrosion, making it reliable for high-load, repetitive motion applications.Â
Utilized for automotive safety parts, AHSS materials offer superior crash performance due to their ultra-high tensile strength and flexibility. These steels allow thinner designs while maintaining the same load-bearing capacity, reducing vehicle weight without compromising safety.Â
Offering an excellent strength-to-weight ratio and corrosion resistance, titanium alloys are ideal for aerospace, medical implants, and high-performance automotive parts. They withstand high temperatures and extreme environments while maintaining structural integrity.Â
Maximizing Precision in High-Speed Production Runs
Precision is maintained through optimized tooling design and advanced maintenance practices in high-speed compound die stamping. Regular tooling inspections and adjustments are implemented to reduce wear, ensuring consistent part quality. Frigate uses precise process control to maintain accuracy, even during rapid production cycles. This approach minimizes defects and extends tool life, ensuring reliable results with every cycle.Â
Compliance for Compound Die Stamping Services
Compliance for Compound Die Stamping at Frigate ensures strict adherence to industry regulations, quality control, and safety standards. These measures are vital for producing precise components while minimizing environmental impact and operational risks. Each certification validates Frigate’s dedication to maintaining high standards in every production stage, from design to final product delivery.Â
Ensures adherence to quality management standards, promoting consistency, process control, and continuous improvement in all operations.Â
Focuses on environmental management, helping reduce waste, energy use, and the environmental footprint of manufacturing processes.Â
Applies to automotive suppliers, emphasizing high-quality production, traceability, and adherence to strict industry standards for component manufacturing.Â
Ensures workplace safety by implementing proper safety protocols and hazard prevention measures for employee well-being.Â
Restricts the use of hazardous substances in electrical and electronic equipment, ensuring compliance with European environmental standards.Â
Governs the use of chemicals and materials in the European market, ensuring safe and environmentally friendly substances.Â
Certifies the flame retardancy of materials, ensuring they meet safety standards for use in electrical applications and components.Â
This act requires transparent sourcing of materials to ensure components are free from conflict minerals, complying with U.S. regulations.Â
Tolerance for Compound Die Stamping Services
Defines the gap between the die punch and die cavity, crucial for controlling material flow and precision.Â
Refers to the deformation that occurs after the material is stamped, requiring compensation during design.Â
Ensures accurate positioning of holes relative to part edges or features for proper assembly alignment.Â
Tolerance for the width of stamped slots, ensuring precise fit for mating parts or inserts.Â
Refers to the tolerance in positioning the stamped edge relative to the part's reference axis.Â
Tolerance related to the flatness and shape retention of the part after stamping, minimizing distortion.Â
Tolerance for the radius of corners, ensuring smooth transitions without excessive sharpness or defects.Â
Defines the maximum allowable deformation of material during stamping without causing failure or fracture.Â
Controls the height of any raised beads or ribs formed during stamping, essential for part functionality.Â
Tolerance range for variations in material thickness, critical for consistent stamping and part integrity.Â
Tolerance for angles formed in deep drawing or bending operations, affecting part geometry and assembly fit.Â
Tolerance for applied coatings (e.g., galvanization or paint) to ensure durability and corrosion resistance.Â
Tolerance in the radius of bends, crucial for part integrity and to avoid cracks or material stress.Â
Tolerance for depth of punch penetration, critical for forming accurate holes and features.Â
Quality Testing Standards for Compound Die Stamping Services
Tests material's ability to undergo deformation without cracking during the forming process.Â
Measures how material properties change under different deformation speeds, ensuring performance in varying conditions.Â
Assesses material's resistance to deformation after initial forming, important for predicting long-term performance.Â
Measures the material's ability to stretch or deform before breaking, ensuring robustness in parts under stress.Â
Tests how much the material can stretch at the edges without failure, critical for deep drawing operations.Â
Measures the effectiveness of lubrication used during the stamping process to reduce wear and increase die life.Â
Measures variations in material thickness across the stamped part, ensuring consistency in thickness.Â
Assesses the material's ability to withstand sudden forces or impacts, essential for parts subject to shocks.Â
Measures internal stresses within the stamped part, ensuring that they do not negatively affect part performance or integrity.Â
Measures the material's ability to strengthen through plastic deformation, essential for high-performance parts.Â
Evaluates how well die materials withstand wear over time, ensuring longevity of tooling and reduced maintenance costs.Â
Assesses the material’s grain structure and hardness to verify consistency and prevent material failure.Â
Tests the material’s stability under repeated heating and cooling cycles to ensure it can withstand thermal changes in use.Â
Measures the decrease in stress over time at a constant strain, ensuring long-term dimensional stability of parts.Â
Optimizing Aerospace Component Manufacturing with Compound Die Stamping
Compound die stamping enhances aerospace component manufacturing by offering high precision and tight tolerances. The process integrates multiple forming steps into a single stroke, reducing setup times and increasing production speed. It supports the use of lightweight, high-strength materials essential for aerospace applications. The stamping process ensures consistent part quality while minimizing material waste. Tooling is optimized to reduce wear, extend tool life, and maintain accuracy over long production runs. This efficient, precise approach ensures aerospace components meet stringent performance and safety standards.Â
Industries We Serve
What You Get
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
Ensuring Consistent Tight Tolerances Across Large Production Volumes
Frigate ensures tight tolerances across large production runs with precise die design and continuous monitoring. Advanced technology tracks material behavior, adjusting process parameters to maintain consistency. Tooling is regularly inspected and calibrated to minimize wear, ensuring dimensional accuracy throughout production. This approach guarantees high-quality, consistent parts from start to finish.Â
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
Compound die stamping integrates multiple operations in one press stroke, which reduces variability. This ensures that intricate features and tight tolerances are consistently achieved, even for complex designs, minimizing the need for secondary operations.Â
Material hardness directly affects tool wear and part formability. Harder materials can cause excessive tool wear, slowing down production rates. However, proper die design and material selection optimize tool life and maintain part quality while effectively managing material challenges.Â
The process is optimized for high repeatability, where precise tooling design ensures consistent part formation with minimal setup changes. This reduces cycle times while maintaining the accuracy and surface finish required for large-scale production runs.Â
Routine die maintenance is critical for ensuring the tooling remains sharp and wear-free. This maintains high precision, prevents defects, and ensures continuous production without unplanned downtime, preserving part quality throughout the production cycle.Â
Compound die stamping utilizes integrated die setups that maximize material utilization by optimizing part placement and reducing scrap. The process minimizes material waste by efficiently using every portion of the material, especially for complex or multi-feature parts.Â
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LOCATIONS
Global Sales Office
818, Preakness lane, Coppell, Texas, USA – 75019
Registered Office
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
Operations Office
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ã…¤
