Metal Stamping Services — Complete Guide

Metal stamping is a high-speed, cost-effective manufacturing process that converts flat metal sheets into finished parts using dies and presses. It's the preferred process for high-volume production of metal components — from tiny electronic terminals to large automotive body panels.

This guide covers metal stamping processes, die types, materials, tolerances, and how to optimize parts for stamping.

Metal Stamping Processes

Progressive Die Stamping

The most common high-volume stamping process. A metal strip feeds through a series of stations — each station performs one operation (pierce, cut, bend, form) until the finished part is cut from the strip at the final station.

Advantages:

• Extremely fast (500-1,500 strokes per minute)
• Minimal labor (automatic feeding)
• Consistent quality (all operations in one tool)
• Ideal for volumes 50,000+

Transfer Die Stamping

Individual workpieces move from station to station using mechanical transfer systems. Used for larger, more complex parts.

Advantages:

• Handles larger parts than progressive
• Allows more operations per part
• Easier die maintenance (individual die sections)

Deep Draw Stamping

The punch pulls the metal sheet into a die cavity, forming a deep, cup-like shape. Used for battery cases, cans, sink basins.

| Parameter | Range |

|---|---|

| Draw depth | Up to 3× diameter (single draw); can exceed with multiple draws |

| Wall thinning | Can exceed 50% at corners |

| Applications | Battery cases, hydraulic cylinders, kitchen sinks |

Fine Blanking

A specialized stamping process that produces parts with perfectly smooth edges (no die break). Uses a third V-ring action to clamp the material.

Advantages:

• Smooth edges (no secondary deburring)
• Tight tolerances ±0.01mm
• Flat parts (no distortion)

Die Types

| Die type | Description | Typical volume | Relative tool cost |

|---|---|---|---|

| Single station die | One operation per press stroke | 1,000-10,000 | $ |

| Compound die | Multiple operations in one station | 5,000-50,000 | $$ |

| Progressive die | Multiple stations, continuous strip | 50,000-10M | $$$ |

| Transfer die | Individual parts between stations | 20,000-500,000 | $$$ |

| Line die | Multiple presses with separate dies | 10,000-200,000 | $$ |

| Fine blanking die | V-ring, smooth edge | 10,000-500,000 | $$$$ |

Material Selection

| Material | Gauge range (mm) | Formability | Strength | Typical use |

|---|---|---|---|---|

| Cold rolled steel (DC01/SPCC) | 0.3-3.0 | Excellent | Good | Brackets, enclosures, frames |

| Hot rolled steel (DD11/SPHC) | 1.5-6.0 | Good | Good | Thicker structural parts |

| Galvanized steel (DX51D/SGCC) | 0.5-3.0 | Good | Good | Corrosion-resistant parts |

| Stainless steel 304 | 0.3-3.0 | Fair | Good | Medical, food equipment, automotive |

| Stainless steel 301 (full hard) | 0.2-2.0 | Fair | Very high | Springs, clips, battery contacts |

| Aluminum 5052 | 0.4-3.0 | Excellent | Moderate | Electronics, automotive panels |

| Aluminum 6061 | 0.8-3.0 | Fair | Good | Structural parts (better machined) |

| Copper C110 | 0.2-2.0 | Excellent | Low | Electrical terminals, bus bars |

| Brass C260 (cartridge brass) | 0.2-2.0 | Excellent | Moderate | Connectors, ammunition, decorative |

| Spring steel (C75S/SK5) | 0.2-2.0 | Fair | Very high | Springs, clips, washers |

| Phosphor bronze | 0.1-1.5 | Good | Good | Electrical contacts, springs |

Design Guidelines

Part Design Rules for Stamping

• Minimum corner radius: 0.5× material thickness (internal); 1.0× (external)
• Minimum hole diameter: 1.0× material thickness (piercing)
• Hole-to-edge distance: 1.5× material thickness minimum
• Distance between holes: 2× material thickness
• Minimum slot width: 1.5× material thickness
• Web width (between features): 2× material thickness
• Minimum bend radius: 0.5-1.0× material thickness (soft steel); 1.5-2.5× (aluminum)
• Minimum flange length: 4× material thickness
• Relief notch (at bends): 0.5-1.0mm deep minimum

Progressive Die Strip Layout Rules

• Carrier strip: 5-8mm minimum width (holds parts during progression)
• Pitch (step distance): 20-40mm for small parts; 50-100mm for medium
• Bridge (between part and strip): 1.5-2.5mm (varies by material and thickness)
• Pilot holes: At least 2, placed at the beginning of the strip

Deep Draw Design Rules

| Draw depth ratio | Number of draws needed |

|---|---|

| Up to 1.5× diameter | Single draw |

| 1.5-2.0× diameter | Two draws |

| 2.0-2.8× diameter | Three draws |

| 2.8×+ diameter | Annealing between draws |

Tolerances

| Feature | Standard (±mm) | Precision (±mm) |

|---|---|---|

| Part dimensions up to 100mm | 0.15 | 0.08 |

| Part dimensions 100-300mm | 0.25 | 0.12 |

| Hole diameter (pierced) | 0.08 | 0.03 |

| Hole-to-hole center | 0.15 | 0.08 |

| Bend angle | ±1° | ±0.5° |

| Flatness (per 100mm) | 0.25 | 0.12 |

| Burr height | 0.1mm max | 0.05mm max (fine blanked: no burr) |

Cost Factors

| Factor | Cost impact | Why |

|---|---|---|

| Material thickness | Progressive below 3mm is efficient; above 3mm needs heavier press | Increases tonnage requirement |

| Part complexity (number of stations) | More stations = more expensive die | Progressive dies cost $5,000-50,000+ |

| Tolerance | Precision adds 20-40% to die cost | More stations, more careful construction |

| Volume | High volume amortizes tool cost | Die cost spread over more parts |

| Material type | Stainless/high-strength wears dies faster | Advanced tool steel coatings needed |

| Surface finish | Secondary operations add cost | Vibratory finishing, deburring, plating |

Stamping vs Alternative Processes

| Factor | Metal Stamping | CNC Machining | Sheet Metal Fabrication |

|---|---|---|---|

| Best volume | 5,000-10M | 1-1,000 | 10-10,000 |

| Per unit cost at 100K | $0.05-0.50 | $5-50 (not practical at 100K) | $0.50-3.00 |

| Tolerance | Excellent (±0.05mm) | Excellent (±0.025mm) | Good (±0.2mm) |

| Setup cost | High (die cost) | Low (CAM programming) | Low |

| Material utilization | Good (nesting reduces waste) | Poor (up to 50% scrap) | Good (nesting) |

| Part complexity | Limited by die construction | Almost unlimited | Good |

| Lead time (tooling) | 6-12 weeks | 1-2 weeks | 1-3 weeks |

Why MFGABC for Metal Stamping?

• Press range: 25 to 800 ton mechanical presses
• Die types: Progressive, transfer, compound, fine blanking, and deep draw dies
• Materials: Carbon steel, stainless, aluminum, copper, brass, spring steel, phosphor bronze
• Thickness range: 0.1mm to 6.0mm
• Finishing: Tumbling, vibratory deburring, plating (zinc, nickel, chrome), powder coating
• Quality: In-process SPC, PPAP documentation available for automotive/medical parts
• Secondary ops: Welding, assembly, tapping, heat treatment available in-house
• Tooling: In-house die design and manufacturing — no third-party tooling delays

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*Submit your part drawings for a free metal stamping feasibility review and quote.*

*→ Next: [Die Casting Services Guide](/capabilities/die-casting/)*

*→ Related: [Sheet Metal vs 3D Printing](/blog/sheet-metal-vs-3d-printing/)*

*→ Related: [Injection Molding vs Die Casting](/blog/injection-molding-vs-die-casting/)*