10 Steps to Convert Machined Prototypes to Progressive Die Stamped Parts

Once you have a prototype made, what’s your next step? Even if the prototype was made using traditional machining capabilities, you have other fabricating options that may offer you more in terms of cost and time savings.

For your next project, consider converting traditionally machined prototypes into progressive die stamped parts. Utilizing progressive die stamping for full production runs of components can be a major source of cost savings. Changing fabrication methods is a source of maximizing efficiency and minimizing costs. Reducing a project’s bottom line is something everyone should think about.

It isn’t a difficult task to go about switching manufacturing processes and we make it even easier. With our in-depth knowledge and over 50 years of experience in the industry, Keats is your partner in realizing the full benefits of progressive die stamping.

10 Steps to Convert to Progressive Die Stamped Parts eBookVarious Fabrication Processes

Even if a prototype was fabricated through traditional machining operations doesn’t mean that machined parts can’t be produced using a different fabrication process. Utilizing innovative solutions, such as progressive die stamping, that are more cost effective over traditional machining operations should be considered before beginning full production of machined prototypes.

Utilizing a comprehensive and highly evolved 10-step plan, we examine every aspect of the process. From prototype analysis through to long-term, high volume maintenance considerations, Keats assists in every aspect of part migration.

Keats’ 10 Steps to Progressive Die Stamping

To help you appreciate our attention to detail, we have published an eGuide that lays out the 10-step process we follow. By downloading 10 Steps to Convert Your Machined Prototype to a High Volume Progressive Die Stamped Part you will see what happens in each part of the process.

These 10 steps include analysis of the prototype, designing the part for manufacturability tool design, and production scheduling. The goal throughout this process is to provide maximum value for your high volume parts. Running through these steps gives you an idea of how the progressive die stamping process, and Keats in particular, can maximize efficiency while minimizing costs.

Download eBook: 10 Steps to Convert to a Progressive Die Stamped Part
Once you have looked through 10 Steps to Convert Your Machined Prototype to a High Volume Progressive Die Stamped Part, feel free to contact us to learn more about how Keats can help you improve your bottom line.

Material Considerations: Copper Alloys and Applications

At Keats Manufacturing, we use a wide range of copper types for our stampings. These include hundreds of different alloys all engineered for different grades of quality in several areas: conductivity, machinability, strength, and corrosion resistance.  As copper is the most conductive non-precious metal, each alloy is an attempt to improve other characteristics of the material without compromising the quality of the connection beyond what is required by the application.
Often the factors come down to price and availability, as many different alloys and materials will fit the bill for various types of applications.  The three we see most often here at Keats Manufacturing are straight coppers, beryllium coppers, and brasses.
Straight copper, again, is the most conductive non-precious metal, making it ideal for electrical conductivity.  However, most applications do not require the conductivity that pure copper provides, and so other alloying metals are introduced to lower cost, improve workability, and maintain conductivity.
Brasses offer the lowest cost and highest malleability. Brasses are zinc and copper alloys where the quality of conductivity is determined by zinc content.  Brass is used in many applications because of its affordability and ease of machining.  However, its susceptibility to corrosion limits its use to controlled or closed environments, often in electronics and enclosed homes and commercial wiring applications.  Beryllium coppers on the other hand have superior corrosion resistance and higher strength than their brass counterparts.  Consequently, they are used in locations either more susceptible to corrosion, or in settings where quality of contact is of utmost importance, like communication or aerospace industries. 
We’re sure as time goes on, more and more effective materials will be engineered for ever more specific applications – with our stamping expertise and experience continuing to serve our customers, whatever materials they choose to use.