Custom metal stamping plays a critical role in modern manufacturing for creating specific parts that have particular functions. It’s used across a wide range of applications, such as creating micro-components for medical devices and producing large parts for industrial machinery. Regardless of the use case, the custom metal stamping process offers a cost-effective, versatile solution for industries needing tailored components. Here, we’ll provide an overview of custom metal stamping’s benefits and applications to help you determine whether it’s the right process for your needs.
What is Custom Metal Stamping?
Custom metal stamping is a manufacturing process capable of creating precise metal parts tailored to your specific needs. This method is often chosen when producing unique parts requiring complex dimensions and a high degree of accuracy. The process starts by designing a custom tool or die that cuts and shapes the metal into the desired form as it passes through the stamping press. Due to its flexibility, custom metal stamping can be used to create everything from large automotive and appliance components to miniature parts for electronics.
Benefits of Custom Metal Stamping
Custom metal stamping offers a wide range of benefits that make it a go-to choice for producing specialized parts and components:
Cost-Effectiveness
One of the primary advantages of custom metal stamping is its cost-effectiveness. It allows for the high-speed production of large quantities of parts, thereby lowering per-unit costs. In addition, precisely cutting and shaping metal lowers material waste, which further improves cost savings.
Accuracy and Reliability
Custom metal stamping achieves unmatched accuracy, which is essential for ensuring that parts meet tight tolerances and perform reliably in demanding applications. For instance, industries like robotics and medical devices rely on precisely stamped parts to maintain functionality and safety. Custom metal stamping ensures that every component is manufactured to exact specifications so you can feel confident that they will perform as needed.
Compatibility with Complex Designs
Off-the-shelf components often fall short of meeting unique design requirements. Custom metal stamping offers the flexibility to create parts that perfectly match complex dimensions and other design requirements. With custom metal stamping, you can tailor components to your unique specifications, ensuring they are the exact right size and shape for your application.
Enhanced Durability
Custom metal stamping can produce parts capable of withstanding rigorous use and challenging environments. Whether for automotive applications or industrial machinery, the durability of stamped components ensures a longer lifespan, reducing the need for frequent replacements and repairs.
Versatility in Design
Custom metal stamping provides unparalleled versatility in creating complex and unique designs. Manufacturers can produce parts in a variety of shapes, sizes, and materials to suit diverse applications. This adaptability enables businesses to innovate and create products that stand out in the market.
Applications of Custom Metal Stamping
Due to its many benefits, custom metal stamping is an ideal choice for a wide variety of applications, including but not limited to:
Automotive: Custom metal stamping enables high-quality, cost-effective production of components like brackets and clips or larger parts for vehicle assemblies.
Electronics: Custom metal stamping enables the manufacturing of precise electronic components like connectors, pins, frames, terminals, shields, and more. High-precision stamping ensures these components meet stringent requirements for quality and functionality.
Oil and gas: Custom metal stamping can create durable parts such as small seals, connectors, and large pipeline components capable of withstanding harsh oil and gas environments. Depending on the metal used, custom metal stampings can endure exposure to salt, high moisture levels, and temperature extremes.
Medical: Custom metal stamping is used to produce medical devices, surgical instruments, and implantable components that meet standards for precision and sterility.
Appliances: Custom metal stamping can create precise components for all kinds of residential and commercial appliances, including refrigerators, ovens, thermostats, outdoor grills, HVAC units, and much more.
Custom Metal Stamping at Keats Manufacturing
Custom metal stamping offers unmatched precision, cost-efficiency, and versatility, making it an invaluable process for industries ranging from automotive to medical. By choosing custom metal stamping, businesses can ensure that their components meet exact specifications while optimizing production efficiency.
Keats Manufacturing specializes in delivering high-quality custom metal stamping services tailored to unique needs. Whether you’re seeking to produce small, intricate components or large, durable parts, our team has the expertise and technology to bring your vision to life.
Ready to explore how custom metal stamping can benefit your business? Contact us or request a quote today!
Avoiding defects is a major goal in metal stamping. Over time, machinery needs recalibration, and punches and tools need sharpening or realignment. If these issues are ignored, stampings may drift out of tolerance, leading to extra time and money for rework.
Your stamping partner should value quality control as much as you do. At Keats Manufacturing, we are always watching for defects and out-of-tolerance stampings during manufacturing and with specialized inspection methods. Keep reading to learn more.
Defect Rates
In small production runs, it’s often possible to inspect individual stampings manually – this is not so much the case at high volumes. Defect rates can soar if problems are not fixed early. Stampers turn to inspection methods that use computers and automation to find defects and errors while maintaining efficiency.
One option is coordinate measuring machines or CMMs. These devices use delicate probes or vision cameras to physically or optically assess a part’s dimensions and features. By comparing the part against stored coordinate data or a digital image, CMMs identify when a part is out of tolerance.
To speed up the process, specialized fixturing is used to position multiple parts for inspection at once. This helps operators maintain their workflow while incorporating quality control.
Forming and Dimensional Defects
Forming and dimensional defects can occur as a result of the material used, worn or improperly assembled tooling, or design problems like defect-prone part features or specifications that are challenging to achieve.
Defects or problems that appear repeatedly signal a stamping error. Identifying and resolving them quickly makes it easier to avoid scrap and rework and minimizes the risk of defective parts reaching you or your customers.
Forming Defects
Metal forming is the process of changing the shape of a metal workpiece without adding or removing material. Common examples of forming defects include:
Cracking and tearing
Galling or scratching
Misalignment or shifting inside the press
Incorrect punch or guide angles
Dimensional Defects
Metal stamping involves changing the shape of a workpiece by cutting, punching, shearing, blanking, or otherwise removing material to create a finished part. Defective parts are often out of tolerance, which affects their fit and function in an assembly or finished product.
Common sheet metal stamping defects include:
Twisting, wrinkles, or improper flatness
Incorrect hole placement, size, or shape
Incorrect bend angles or springback
Burrs and deformed edges
Overall part length/width defects
Stamping defects are often caused by a misaligned material feed, worn or broken punches, material defects, improper force or tonnage, or other problems.
Packaging Defects
Packaging mistakes can also lead to damaged parts, scrap and rework, fulfillment delays, and extra expenses.
Incorrect or Missing Shipping Markings and Barcodes
Incorrect barcodes or labels in the wrong place are inconvenient in smaller orders, and it only compounds in a high-volume production run. It takes time and money to relabel dozens or hundreds of boxes and cases, or to recheck part numbers, shipping info, or dimensional details. That in turn causes fulfillment delays, so it’s critical that inspection includes checks for these errors.
Container and Product Defects
Components may be packaged manually by workers or with automated or semi-automated equipment, or even a combination. Regardless of the method, parts can be damaged if they are packed incorrectly, jostled and scratched, or if the packaging itself is damaged, bent, or torn. Some packaging methods like tape and reel encapsulation for very small parts, or custom trays to isolate individual parts, can prevent damage during packaging.
Another important step is the final inspection of packed parts. This ensures packaging is correct and no defective parts were missed in earlier inspections. It can be done by workers as they pack items or with machine vision equipment, comparing an image of a correctly packed tray or box with items as they exit the packaging line.
Metal Stamping Services From Keats Manufacturing
Errors and defects can happen at many points in the stamping and packaging process. That’s why you should work with a manufacturer who prioritizes attention to detail at every turn and has taken the steps to mitigate the risk of defects.
At Keats Manufacturing ee are ISO:9001, ISO:14001, and IATF:16949 certified. We provide high-quality metal stamping and finishing services with careful inspection and packaging to meet your needs. Contact us to learn more or request a quote to start your order.
When an off-the-shelf clip just won’t get the job done, you can turn to the experts at Keats Manufacturing Co. to manufacture your custom clip exactly to your spec. We specialize in the design, manufacturing, and assembly of high volume custom metal clips for a broad range of applications, including highly technical industries requiring the tightest possible tolerance windows and specialized materials. To produce our extensive range of wire clip shapes and sizes, we use Four-Slide / Multi-Slide metalforming machines and mechanical punch press machines. We utilize a number of secondary services such as deburring, austempering, plating and dip spin coatings. Over 300 different custom clips are produced at Keats’ multiple state-of-the-art production facilities.
Read on to learn more about how we provide customers with the most effective metal clips of any shape, size, and material using industry-leading metal stamping technology and exacting quality controls.
Different Shapes for Clips
Our production expertise and facility capabilities extend beyond simple shapes and include a wide range of complex custom designs based on our client’s exact needs. Some of Keats Manufacturing’s most heavily relied on metal wire clips include:
U-clips
C-clips
S-clips
D-spring clips
Solar Panel array wire management clips
Flat spring clips
Dart clips
Round metal clips
Terminal clips
Tubular clips
Metal hinge clips
Industrial metal shelf clips
Materials for Custom Metal Clips
Our experienced fabrication technicians are adept at shaping a vast range of source material types, providing our customers with innumerable choices. We can design, prototype, and fabricate custom metal clips made from metals as varied as:
Aluminum
Phosphor bronze
Beryllium copper
Low carbon steel
High-carbon steel
Stainless steel
Nickel
Brass
Keats Manufacturing’s metal clips are crucial components in many industries and technologies, including the automotive, communications, construction, aerospace, and military sectors, along with medical devices, solar panels, home appliances, electrical components, and much more.
There’s virtually no general manufacturing procedure that doesn’t require metal wire clips in at least some part of the process. We work carefully with each customer to fully understand their custom metal clip needs and ensure the finished product is exactly the right solution for their needs.
Benefits of Our Metal Clip Services
The Keats difference means customers never have to compromise on quality or customer service. Our experienced tool and die makers are equipped with advanced CAD/CAM, CNC, and EDM technologies that make more detailed and effective designs possible. From prototypes to full-production runs, we ensure every product adheres to the most stringent quality standards by collecting and analyzing a comprehensive range of production data.
The end result is total certainty that each customer receives the most effective metal clips, all at an affordable price and with just-in-time delivery. Customers across numerous industries can rest assured that our facilities are compliant with ISO 9001, ISO 14001, and IATF 16949 standards. To provide current and prospective clients with maximum confidence, we make copies of our updated certifications and other credentials available for download at any time.
No matter where our clients are located or how complex and large-scale their projects are, we always deliver final products of the utmost quality, on time, and at a competitive price.
Rely on Keats Metal Clip Services
Since 1958, Keats Manufacturing has advanced the field of precision metal engineering to meet the stamping and fabrication needs of countless global industries. We’ve outfitted our facilities with the best manufacturing equipment and QA procedures, making us fully capable of advanced design and prototyping processes, up through multi-million-part production runs with maximum efficiency.
If your company has any metal clip or other stamping needs, contact us or request a quote. Our highly knowledgeable representatives are standing by to learn about your metal fabrication needs.
Compound, progressive, and transfer die stamping are all methods used to produce metal stamped parts for many industries. The three die stamping methods allow manufacturers to meet unique design specifications, tolerances, and volumes, but it is crucial to choose the right process method that meets your needs.
Compound Die
Compound die stamping is a metal stamping method that simultaneously performs multiple bends, punches, or cuts in a single stroke. It is ideal for producing flat parts like washers and wheel blanks in medium or high volumes. Compound die stamping is a high-speed stamping process, but larger components can take longer to exit the machine, reducing the overall speed.
Compound die stamping delivers various benefits to manufacturers. The benefits of using compound die stamping include:
Less costly tooling than progressive die tooling
Efficient and fast production of simplistic and small parts
Facilitates high repeatability of single-die cases
One stroke produces flatter parts
Progressive Die
Progressive die stamping can produce parts with tight tolerances in large volumes. This stamping method can simultaneously shape, bend, and punch parts from a metal coil that is fed through the stamping press.
In progressive die stamping, the workpiece stays attached to the metal strip from start to finish. The part is removed only in the final step in the stamping process. This process is compatible with a range of materials; however, it requires costly steel tooling and is not suitable for parts requiring deep drawing.
Progressive die stamping provides several benefits, including:
Saves time and money by performing multiple operations simultaneously
Reduces waste
Can perform long production runs
Lower labor costs and reduced setup
Permits complex geometries
Can quickly produce large runs of small parts with exacting tolerances
Transfer Die
Transfer die stamping starts by separating the workpiece from the metal strip to focus on the individual part. The process relies on automation to transport and align the workpiece to several stations, each performing a different operation. The multiple-step process of transfer die stamping allows for designs with high levels of intricacy, including threading, ribs, and knurls.
Transfer die stamping is suitable for manufacturing deep drawn parts because the metal strip’s removal occurs at the beginning of the stamping process. It is also ideal for manufacturing tubes and applications that require a workpiece separate from the metal strip.
Transfer die stamping provides the following benefits to manufacturers:
Cost-effective for small production runs
Improved versatility
Efficiently produces complex and intricate parts
Suitable for large parts
Reduces the need for secondary operations for specialized parts
Metal Stamping From Keats Manufacturing Co.
Metal stamping is an efficient method of creating various parts from a strip of metal material using a die and press system. Because each type of metal stamping method has its differences, it’s important to work with an experienced partner that understands each process and can help you determine the best option for your needs.
At Keats Manufacturing Co., we deliver custom metal stamping using various die stamping methods. Our industry-leading metal stamping capabilities allow us to fulfill order quantities in a range of sizes and provide support from prototyping to production. For more information on our metal stamping capabilities, or for help choosing the right metal stamping method for your project, contact us or request a quote today.
Modern cars have a range of electrical connectors and terminals that control the internal system. This complex equipment controls and operates dozens of functions while providing critical real-time information to the driver. As the world makes the transition from ICE (Internal Combustion Engine) to electric-powered vehicles, the technology and components needed to support that transition will change as well. The main components of an ICE vehicle’s electrical system are the starter, battery, and alternator. The battery is a source of energy for the starter, while the alternator provides power to the car.With electric vehicles, there is no longer a need for a starter or alternator. The main battery provides enough power for the propulsion of the vehicle as well as the operation of all of the other components within the vehicle.
How Does Your Car’s Electrical System Work?
The primary function of a car’s electrical system is to generate and store energy while supplying electrical current to power the various car systems, including power windows, digital devices, electrical gauges, a central locking mechanism, and more. This system offers precision control and convenience of operations.
The electrical system is incorporated throughout the vehicle to ensure communication between all parts of the car with the help of a central computer. Power is distributed from the main battery through a PDU (Power Distribution Unit) to all of the other components within the vehicle.
Most electric car batteries operate between 300-800 volts which is substantially different from the traditional 12 volts from ICE vehicles. This system has very different requirements for components. Since the battery provides the power needed to propel the vehicle as well as operate all of the different functions and controls these cars have circuits with high amperage and bigger parts to efficiently bear the load without failure.
Vehicle Electrical System Precision Metal Stamped Parts
How does Keats play a role in the automotive electrical system? We produce precision metal stampings, wire forms and assemblies. We specialize in copper alloy parts which can be found in nearly every component within the vehicle electrical system. Some examples of the components which Keats supplies parts for are ECU (Electronic Control Unit), Power Steering Sensor, Internal and External lighting systems, Adaptive Suspension Sensor, Ignition Coil, Fuse Box and many more
Some of the main components of a car’s electrical system include the following:
Terminals
A terminal is a conductor attached to the end of a wire within the vehicle that easily connects the various electrical parts within your car. Nearly all of the terminals within a vehicle are produced using the progressive stamping process. Once produced they are crimped to the ends of wires and become part of a larger wire harness. These terminals are responsible for electrical conductivity by providing power to the vehicle’s systems along with mechanical and electrical resistance to withstand harmful elements. Therefore, the durability and high quality of the car terminal connectors are crucial.
Bus Bars
Bus bars are an amazing engineering feat that helps make complicated systems of power distribution simple, flexible, and more affordable. The battery bus bar is typically located inside the panel boards, busways, or switchgear and conducts an electrical current. This component enables the new electrical circuits to branch off at any place along the busway route, rather than branching off the primary supply at a single location. The car battery terminal bus bar connects high-voltage equipment with low-voltage devices within battery banks and high-voltage devices with electrical switchyards. There are also busbars located within the fuse box which play a key role in distributing electricity throughout the vehicle. Busbars are almost always made from copper. Keats specializes in the production of automotive bus bars using progressive die stamping and stage tooling in order to ensure the most stable and cost-effective production of these critical components.
Wire Harnesses
Wire harnesses are bundled wires and data circuits, but they are so much more than that. Think of a wire harness as the nervous system of the vehicle. Every switch, light bulb, sensor, assembly, regulator, gauge, or button needs to receive power from the wire harness and oftentimes provide a signal back to another component. As vehicles become more and more complex through the use of sensors, the need for more complex wire harnesses with more connection points becomes larger. At Keats, we specialize in developing the terminals that attach to the end of each and every wire in the harness and work directly with our customers to develop custom stamped terminals and connectors to meet the changing needs of the electric vehicle market.
Switches
The EV switches within the car’s electrical system shut off or switch the power supply off from a battery circuit system. These switches protect the car as well as those around it from accidental electrical shock. The most common or easily recognizable example of an automotive switch is the one used to raise and lower the windows. Switches provide high-performance safety due to their interlocking design, which prevents a false power supply. Keats supplies critical components that are used within these switches such as spring terminals.
Custom Solutions From Keats
A car’s electrical system needs quality parts to ensure its maximum, safe performance. Keats is a leading automotive parts manufacturer that provides a wide range of high-quality, durable custom car electrical system parts, including bus bars, connectors, car battery terminals, and more. We use state-of-the-art technology and our industry expertise to provide you with premium-quality electrical system car parts that deliver superior performance and give you maximum return.
We are certified to IATF:16949, ISO:9001 & ISO:14001 so you can rest assured that we have the experience and the quality system necessary to meet the changing needs of today’s automotive electrical system market.
