Metal stamping is an efficient and cost-effective way to transform flat metal sheets into all sorts of shapes and components. It can be achieved by using specialized machine press tools.

In this beginner’s metal stamping guide, we will cover all the essential things every newcomer should know before diving into this versatile process. So let’s get started!

What is Metal Stamping?

Metal stamping involves using specialized tools and machines to shape metal sheets or coils into desired forms and components. It is widely used in manufacturing industries like automotive, aerospace, electronics, and consumer goods. It is a versatile and cost-effective way to produce metal parts in large volumes with consistent quality.

The Complete Kit for Metal Stamping

Hand metal stamping is a convenient and creative way to add a personal touch to various items like jewelry, cell phone cases, bag accessories, pet tags, and more. It allows you to express yourself through meaningful phrases, words, decorative icons, or simply personalize with initials.

While the essential supplies for hand metal stamping can be quite minimal, there are many optional tools and accessories available for those seeking precision while enjoying collecting stamping gear.

Essential Tools

  • Metal stamps: These stamps are used to impress designs or text onto the metal.
  • Stamping hammer: A specifically designed hammer for metal stamping is used to strike the stamps.
  • Steel block: A solid steel surface to place the metal blanks during stamping.
  • Metal blanks: The metal sheets or pieces that will be stamped.

Optional Tools

  • Metal sheers: Used for cutting basic shapes from metal sheets.
  • Disk cutters: Specialized tools for cutting circular shapes from metal.
  • Jewelers saw: Allows for cutting intricate shapes from metal sheets.
  • Stamp straight tape: Helps keep the metal in place and aids in precision stamping.
  • Texturizing hammer: Used to add texture or patterns to the metal surface.
  • Oxidizing agent or patina: Gives an antiqued or aged look to the metal.
  • Patina inks or paint: Allows for adding color or faux patina effects to the metal.
  • Rubbing alcohol for cleaning: Helps remove residues and prepare the metal for polishing or finishing.

Optional ToolsThe Complete Metal Stamping Design Guide

The following guide presents the recommended practices and formulas used in designing metal stamped parts.

Blanking Stage

Blanking is the process of cutting the rough, basic shape, and it is often the first step in metal stamping.

  • Piercing: Piercing is a common metal stamping process used for forming holes and slots within the edges of a part.
  • Hole Diameter: The minimum hole diameter should be at least 1.2 times the material thickness or larger. Smaller holes require specialized processes, adding to the cost.
  • Hole Geometry/Taper: Punched holes in stamped parts have a tapered profile, and if a constant diameter is needed, additional drilling or machining operations are required, resulting in higher costs.
  • Edge-to-Hole Spacing: The space between a hole and the edge of a part should be at least twice the material thickness to avoid bulging. For oblong slots, the spacing requirements vary based on the length of the slot.

Bending Stage

Bending is one of the substantial forming operations often performed toward the end of the progressive die-stamping process. Metal stamping is a sequential process where one step follows another until the final part is produced. The best-stamped metal part designs take into account the step-by-step nature of the stamping process.

When designing bends in stamped metal parts, there are several considerations:

  • Forming Bends Near Holes: A bend made too close to a hole can cause deformation.
  • Notches, Tabs, and Slots: These features should have widths at least 1.5 times the thickness of the material.
  • Corners: Every corner in the blank design should have a radius that is at least half of the material thickness.
  • Burrs: To minimize the instances and severity of burrs, avoid sharp corners and complex cutouts when possible. Burr allowance is generally 10% of the sheet material thickness.
  • Stamped Edges: When metal is cut or sheared, the downward stress causes the material to fracture once its shear strength is met, creating a burr on the bottom edge of the material.

Coining Stage

Coining the edges of a stamped metal part is sometimes an option to avoid costly secondary processes like vibratory deburring or edge grinding. During the coining process, the edges of the part are struck in a manner that flattens or breaks the burr.

  • Plasticity and Grain Direction: Plasticity is the measure of permanent deformation a material undergoes when subjected to force. For metals with high plasticity, the grain direction is not a major concern, and they generally require an inside bend height at least 20% less than higher-strength metals.
  • Bend Height: When adding a bend or form to a stamped metal part, the height of the bend becomes a design consideration. The thickness of the material plays a role in determining the overall height of the bend from the base material.
  • Bend Relief: If a bend is made too close to an edge, the material on the base of the part along either side of the bent section may tear, significantly reducing the part’s integrity. Therefore, a bend relief area is often required to prevent tearing.

Coining StageBend Distortion/Bulge

In cases where bending distortion or bending bulge is unacceptable, the part can be relieved prior to bending by adding a relief notch on either side of the intended bend area. This helps prevent distortion during the bending process.

Countersinks are a common feature utilized in stamped metal parts when the application requires accommodating various types of fasteners, such as flathead screws. By incorporating countersinks, the fastener heads can sit flush with or below the surface of the part, providing a smooth and uniform appearance.

Carrying Web and “Mismatch” Cut

During the design stage of a new progressive die, it is crucial to discuss with the customer where the part will be carried or held in the strip as it moves through the die. This location, known as the carrying web, is where a “mismatch” cut will occur when the final part is separated from the strip.

The mismatch cut is a necessary byproduct of the progressive stamping process, and its location must be identified during the design phase to ensure proper planning and execution.

The Complete Metal Stamping Guide

Metal stamping is a process that requires careful preparation and execution. Follow this metal stamping process guide to ensure a successful stamping project:

Step 1 – Setting up the stamping block:

Place the stamping block on a sturdy, flat surface. Secure the metal blank to the block using tape or a stamp guide to prevent any unwanted movement during the stamping process.

Step 2 – Spacing and aligning:

Utilize a metal stamp guide to evenly distribute letter spacing and align stamp impressions. Directly write the desired message on the guide and reference the guideline marks for accurate spacing.

Step 3 – Orienting the stamp:

Position the stamp at a 90-degree angle to the stamping blank. If the stamp has a logo on the shank, ensure it faces you to stamp the impression in the right direction.

Step 4 – Aligning the stamp:

Gently drag the stamp towards the corresponding mark on the guide until it catches the guide’s edge, aligning it correctly.

Step 5 – Securing the stamping blank:

Hold the stamp flush and firmly against the blank, applying slight pressure while anchoring your hand on the workspace. Strike the stamp once with moderate force using a metal stamping hammer. Repeat this striking process for each letter, word, or quote desired. Once complete, remove the stamp guide and tape.

The Complete Metal Stamping GuideConclusions

It is essential to have a deep understanding of metal stamping fundamentals to produce high-quality components. Knowing the best practices outlined in this metal stamping guide can help avoid costly errors and ensure that your metal stamped parts meet the required specifications.

For reliable metal stamping services, consider working with Fischer ASIA to ensure the metal stamping quality. We are certificated with IATF 16949 and ISO 9001:2015. Fischer ASIA also adheres to RoHS and REACH standards for safety and continuous improvement.

Check out Fischer ASIA’s metal stamping capabilities by contacting us today to discuss your project needs!

FAQs

In what ways can metal stamping improve the quality and consistency of products, thus benefiting a business?

Metal stamping uses precise dies and automated equipment to produce highly uniform parts. These parts have tight tolerances and minimal variation, even in high volumes. Metal stamping will ensure consistent quality, reduce rework, and improve product reliability.

How can metal stamping enhance the efficiency and profitability of a manufacturing business?

Metal stamping is a rapid, cost-effective process, allowing for high production volumes and economies of scale. Its automation also minimizes labor costs and defects, resulting in greater efficiency and profitability in manufacturing businesses.

What are the potential risks of integrating metal stamping, and how can they be mitigated?

Key risks are the high upfront cost of tooling and the part distortion after stamping. Partnering with an experienced stamping supplier is crucial – they can optimize the process, compensate for distortion, reduce development costs, and ensure a smooth implementation to mitigate risks.