Progressive Die Stamping
Frigate offers progressive die stamping services designed to help business leaders improve their production efficiency. Our team specializes in providing solutions that meet strict production specifications.
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Advantages of Progressive Die Stamping with Frigate
Reduced Tooling Costs
Progressive die stamping requires fewer tools than traditional methods. It combines multiple operations into a single process, lowering overall tooling expenses.
Enhanced Part Complexity
This method can produce intricate part geometries in a single operation, allowing for advanced designs that would be challenging to achieve with other techniques.
Continuous Material Feed
Using a continuous strip of material improves efficiency, as parts are created without interruption, optimizing production flow and minimizing downtime.
Minimal Material Waste
Progressive die stamping maximizes material utilization by strategically nesting parts within the strip, leading to reduced scrap and a more sustainable manufacturing process.
Optimizing Custom Component Production
When selecting the right metal forming process for your custom components, key factors include cost, production volume, and lead times. Progressive die stamping stands out for high-volume production runs, delivering custom parts at medium to fast production speeds. Although setup costs may increase with specific customizations, the rapid production rates significantly lower the price per item manufactured. This balance of efficiency and cost-effectiveness makes progressive die stamping ideal for your production needs.
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Our Progressive Die Stamping Process
The process begins with designing the part and creating prototypes. Engineers use CAD software to develop precise specifications and ensure functionality.
Once the design is finalized, a progressive die is constructed. This die contains multiple stations, each responsible for a specific operation, allowing complex part shapes to be formed continuously.
Raw materials, typically metal strips, are prepared and fed into the progressive die stamping machine.
The machine moves the material through each station in the die. Specific operations, such as cutting, bending, or shaping, are performed sequentially at each station, gradually forming the final part.
After the stamping process, the parts undergo quality inspection. This includes checking dimensions, surface finish, and defects to ensure the component's quality.
Finally, the stamped parts may receive additional finishing processes, such as deburring or surface treatment. Parts are assembled into larger components for further use in various applications if necessary.
Progressive Die Stamping Materials
Progressive die stamping can utilize various materials, each with unique properties that suit different applications. Selecting the appropriate material is essential to getting the intended functionality and longevity out of the finished product.
Steel is the most popular material for progressive die stamping. It is perfect for heavy-duty applications because of its exceptional strength and longevity. Various materials, including carbon and stainless steel, can be employed, offering different degrees of hardness and corrosion resistance.
Aluminum is lightweight and corrosion-resistant, making it an excellent choice for industries like automotive and aerospace. It can be easily formed and machined, allowing for complex designs. Aluminum is often preferred for components that require a good strength-to-weight ratio.
Brass is known for its excellent machinability and conductivity. It is commonly used for electrical components and fittings. Brass parts can be easily stamped into intricate shapes, providing aesthetic and functional benefits.
Copper offers high electrical and thermal conductivity, making it suitable for electronic and electrical applications. Its malleability allows for precise stamping and can be coated for added protection against oxidation.
HSLA steel combines strength with lightweight properties, making it ideal for toughness and weight reduction applications. It is commonly used in automotive parts, where reducing weight can enhance fuel efficiency.
Zinc-coated steel is suitable for outdoor applications and provides corrosion resistance. Its layer protects the underlying steel from rust, ensuring longevity in harsh environments.
Tool steel is specifically designed for manufacturing tools and dies. It offers high hardness and wear resistance, making it essential for producing durable stamping dies that can withstand repeated use.
Innovative Solutions for Complex Challenges
Complex part designs, fluctuating market demands, and stringent quality standards create significant challenges. These factors can lead to inefficiencies and higher costs. Progressive die stamping addresses these issues by combining multiple forming processes into a single operation. This streamlines production and reduces handling times. It allows for the creation of intricate geometries while maintaining tight tolerances. Rapid prototyping is also possible, enabling quick adjustments based on feedback. This flexibility is crucial in fast-paced industries. Progress die stamping enhances productivity and adaptability, ensuring a competitive edge in a dynamic market.
Revolutionizing Automotive Components
The automotive industry faces increasing demands for efficiency, precision, and cost-effectiveness. Challenges like tight production schedules and the need for high-quality components can strain resources. Progressive die stamping addresses these issues by enabling the rapid production of complex parts with tight tolerances. This method allows for multiple operations in a single process, reducing handling time and minimizing material waste. With the ability to produce lightweight and durable components, progressive die stamping enhances vehicle performance and fuel efficiency. Automobile manufacturers can improve productivity by adopting this technology while meeting rigorous industry standards.
Industries We Serve In Welding
What You Get
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
Ensuring Precision in Progressive Die Stamping
Tight tolerances are essential in industries like automotive and aerospace. Frigate addresses these challenges with advanced inspection technologies and robust quality assurance protocols. Utilizing coordinate measuring machines (CMM) and automated inspection systems ensures high accuracy and consistency in every stamped component. Regular maintenance and real-time monitoring of production processes further enhance precision. With a commitment to excellence, Frigate consistently delivers stamped parts that meet or exceed stringent industry specifications, ensuring reliable performance and customer satisfaction.
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
The choice of material depends on the part's intended use, mechanical properties, and compatibility with the stamping process. Common materials include aluminum, steel, and brass, each selected for specific strength, flexibility, and corrosion resistance.
Dimensional accuracy is achieved through precision-engineered dies and material-controlled movement during the stamping process. Advanced tooling techniques, such as multi-stage forming and fine-tuning of die clearances, also contribute to maintaining tight tolerances.
Prototyping allows for testing the design and functionality of parts before mass production. It helps identify potential issues and refine the design. This process ensures that the final component meets specifications, reducing waste and production costs.
This process utilizes a continuous feed of material through the die, maximizing the use of raw materials. Efficient nesting of part designs within the die layout further reduces scrap, ensuring more economical production.
High-volume production can lead to wear on dies and tooling, affecting quality over time. Additionally, managing consistent material properties and dealing with variations in raw materials can pose challenges that require ongoing monitoring and adjustments.
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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. ㅤ