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Tag Archive: metal stamping

  1. Key Considerations When Choosing a Metal Stamping Partner

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    Metal stamping is a manufacturing process that employs a specialized press, as well as tool and die set, to form sheet metal into a specified shape and size. Industry professionals employ metal stamping processes to produce a wide range of industrial parts and products. When looking for a metal stamping partner, there are several considerations to bear in mind. You’ll want to vet a company that offers the greatest value for your project.

    The following piece provides an overview of some of the key factors to consider when choosing a metal stamping partner. In addition to metal stamping capabilities, qualities such as a broad selection of other fabrication and finishing services, extensive industry experience, and high quality standards are indicative of a high-value partner.

    Partner vs. Supplier

    When sourcing a metal stamping company, it is important to know the difference between a supplier and a partner. While a supplier has the metal stamping capabilities necessary to fulfill the project, a partner offers the required metal stamping services and more. The latter should be able to assist with all project needs, including design and engineering assistance, manufacturing, and/or finishing services. These offerings help shorten production timelines and reduce production costs.

    Advanced Stamping Capabilities

    While specialization is good, narrow specialization is not. For example, some projects may not overtly indicate which metal stamping process is appropriate. A metal stamping company that offers a wide range of in-house stamping capabilities—e.g., bending, blanking, coining, piercing, etc.—is better able to accommodate such projects. However, for projects that required advanced metalworking—i.e., deep draw stamping—it is essential to work with a specialist to ensure greater precision and accuracy in the finished parts.

    Tooling Design and Development Services

    Metal stamping companies that maintain an in-house tooling design and development team have greater control over part and process quality. As they have the ability to create custom tooling for every project, they are better able to ensure production proceeds as intended.

    Secondary Services

    As indicated above, a metal stamping partner should ideally offer more than just metal stamping capabilities. These secondary operations—provided in-house or through a network of reliable vendors—allow clients to receive a full-service stamping solution. Some of the other fabrication and finishing processes a partner may offer include:

    • Heat treatment
    • Forming and welding
    • Painting and electrocoating
    • Passivation and sterilization
    • Pre-plating and post-plating processes
    • Precious and non-precious metalwork
    • Specialty edge cleaning and deburring
    • Assembly
    • Kitting & Custom Packaging

    Industry Experience

    Regardless of whether you [the customer] are in the aerospace, automotive, construction, appliance, or other industry, any potential metal stamping partner should have experience producing parts and products for your industry. This quality ensures the partner is familiar with any requirements or restrictions specific to the industry (e.g., using FDA compliant materials for medical devices).

    Production Capacity

    Both the type of equipment employed and the lead time for raw material orders estimated affect a company’s production capacity. A metal stamping partner should utilize metalworking equipment that allows them to complete projects efficiently without sacrificing precision or accuracy.

    Precision engineering technician inspecting small part for quality control.

    Quality Management

    The International Organization for Standardization (ISO) develops and publishes standards aimed toward ensuring the quality, safety, and efficiency of products and services. The ISO 9000 family of standards focuses on quality management principles regarding a company’s products and processes. Companies certified to ISO 9001 comply with the ISO’s criteria for quality management systems, meaning they are knowledgeable about best practices regarding quality and sustainability, and are actively and adequately working to integrate them.

    Metal Stamping Solutions From Keats Manufacturing

    At Keats Manufacturing Company, we are an ISO- and ITAF-certified manufacturer of high-quality custom metal stampings, wire forms, and assemblies. Equipped with over 60 years of metalworking experience and three state-of-the-art facilities, our team has the knowledge, skills, and tools to meet virtually any small metal stamping need, ranging in size and design complexity. Our metal stamping capabilities include:

    • Bending
    • Blanking
    • Coining
    • Curling
    • Drawing
    • Embossing
    • Piercing
    • Punching

    We also offer in-house tooling design and development services, which allows us to create die and tools sets that achieve up to ±0.0005 inch tolerances throughout a metal stamping project.

    The industries we serve include:

    Frequently Asked Questions

    When evaluating a metal stamping partner, consider the following:

    • Keats Manufacturing Co. operates one of the largest fleets of four-slide machines in North America, ensuring advanced stamping capabilities.
    • Our unique Wünsch multi-slide machines provide exceptional precision for complex designs.
    • We guarantee high-precision tolerances (±0.0002 in. for stamping) to meet your exact specifications.

    In-house tool and die development is crucial for efficiency and quality:

    • At Keats Manufacturing Co., we manage all tooling in-house, which allows for quick adjustments and reduced lead times.
    • Our tooling comes with a lifetime guarantee, ensuring long-term reliability.
    • This capability supports our commitment to high-volume production without compromising precision.

    ISO certifications are key indicators of quality and compliance:

    • Keats Manufacturing Co. is certified to ISO 9001, ISO 14001, and IATF 16949, ensuring consistent quality standards.
    • Suppliers who are ISO/IATF certified have strong quality systems.
    • Choosing a certified partner like us means you can trust our processes and product integrity.

    Location can significantly affect production efficiency:

    • Keats Manufacturing Co. has three strategically located campuses in Illinois, Texas, and Mexico, optimizing logistics and delivery times.
    • Our facilities are state-of-the-art, equipped to handle various industrial applications efficiently.
    • Proximity can also enhance communication and support throughout the manufacturing process.

     Experience is vital for ensuring quality and reliability:

    • With over 65 years in the industry, Keats Manufacturing Co. brings a rich legacy of expertise and technical knowledge.
    • Our long-standing history has equipped us with the skills to handle complex projects across various sectors.
    • An experienced partner like us can better anticipate challenges and offer innovative solutions.

    Assessing precision capabilities is essential for quality assurance:

    • Keats Manufacturing Co. specializes in high-precision tolerances, achieving ±0.0002 in for stamping.
    • Our advanced machinery and skilled engineers ensure each part meets exact specifications.
    • Requesting sample work can further demonstrate our precision capabilities.

    Understanding manufacturing processes helps ensure they meet your needs:

    • Keats Manufacturing Co. utilizes advanced stamping technologies, including four-slide and Wünsch multi-slide machines, for complex geometries.
    • Our in-house tool and die development means we retain full control of the tooling process from start to finish. 
    • We also employ strict quality control measures at every stage of production to maintain high standards.

    Ensuring high-volume production capability is critical for efficiency:

    • Keats Manufacturing Co. is equipped with one of North America's largest fleets of stamping machines, enabling us to scale production as needed.
    • Our experience with high-volume industrial and engineering applications ensures we can meet your demands without compromising quality.
    • We also implement strict timelines and quality checks to maintain consistency throughout the production run.

    To learn more about our metalworking capabilities or partner with us on your next project, contact us or request a quote today.

  2. Is Precision Metal Stamping Right for Your Application?

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    Precision metal stamping is a manufacturing process that utilizes a custom tool and die set installed in a stamping press to turn sheet metal into the desired components. It is used in a wide range of industries to create large quantities of parts and products with high precision, accuracy, and speed. While this process offers manufacturing advantages, it is not appropriate for every production project.

    The following article discusses some of the considerations to keep in mind when determining whether precision metal stamping is right for your project. It provides an overview of the process, the benefits it offers, and the typical industries that use it.

    An Overview of Precision Metal Stamping

    Metal stamping—also sometimes referred to as pressing—relies on specialized tooling (i.e., a tool and die set) and equipment (i.e., a press) to form metal sheets and coils into the required shape and size. The pressure exerted on the workpiece by the press forces the material to conform to the shape formed by the tool and die. This process can occur in a single stage or across several stages, depending on the simplicity or complexity of the end product. Precision metal stamping operations largely rely on the use of automated equipment, which ensures the finished components are both precise and accurate.

    In addition to higher precision and accuracy, some of the other advantages the precision metal stamping process demonstrates over other manufacturing processes include:

    • Greater product and process quality. Accuracy offered by the precision metal stamping process translates to a lower error rate during production. This means there is a smaller chance of producing faulty or flawed parts making it into the hands of customers.
    • Lower production costs. A generally automated process, precision metal stamping mitigates the need for manual labor. This quality also results in a lower error rate, which translates to less material utilization and waste during a production run.

    Industries Served

    As indicated above, the precision metal stamping process finds application in a wide range of industries. Some of the industries that regularly employ the process for the production of their parts and products include:

    Automotive

    Metal Stamping for AutomotiveIn the automotive industry, stamping is used to create a variety of structural and functional parts used in vehicle bodies and frames, electrical systems, steering systems, and more. Some examples of typical automobile parts made in metal stamping operations include:

    • Brackets and hangers
    • Electrical terminals and connectors
    • Wire forms (e.g., tire and under chassis components)

    Aerospace

    In the aerospace industry, parts and products are subject to strict manufacturing requirements and restrictions. These guidelines are in place to ensure the safety of the aircraft’s personnel and passengers and the public. For this reason, aerospace components manufacturers (e.g., Keats Manufacturing Co.) maintain certification and compliance with various industry standards such as Mil-spec and RoHS. Some of the metal stamped parts and products commonly produced for aerospace applications include:

    • Assemblies
    • Brackets
    • Bushings
    • Clips
    • Lead frames
    • Shields
    • Terminals
    • Wire forms

    Medical Devices

    Metal Stamping for Medical Devices Similar to the aerospace industry, the medical device industry has many standards dictating how a component should be made. These exceptionally high standards ensure the safety of medical practitioners and patients. Standard and custom metal stampings are found in a variety of medical devices, including:

    • Connectors, couplings, and fittings
    • Equipment housing and sleeves
    • Implants and prosthetics
    • Pump and motor components
    • Surgical instruments and equipment
    • Temperature probes

    Electrical Distribution

    Professionals in the electrical distribution industry make use of many different metal stamped parts and products in circuit breakers, distribution boxes, switches, transformers, and other critical equipment. Some examples include:

    • Brackets
    • Clips
    • Contacts
    • Inserts
    • Shields
    • Terminals

    Appliances

    Metal Stamping for Appliances - Washing MachinePrecision metal stampings are found in a wide range of commercial and residential appliances, such as:

    • Automatic garage doors
    • Dishwashers
    • Dryers
    • Garbage disposals
    • Grills
    • HVAC units
    • Irrigation systems
    • Ovens
    • Pool filtration and pump systems
    • Refrigerators
    • Security systems
    • Stoves
    • Thermostats
    • Washers
    • Water heaters

    Renewable Energy

    The renewable energy industry encompasses solar, wind, geothermal, and other clean energy operations. As the industry grows in response to the push for greater sustainability, so too does the need for reliable parts for power generation and distribution equipment and systems. Some of the metal stamped components regularly produced for such applications are:

    • Antennas
    • Brackets and clips
    • Cases, inserts, and retainers
    • Fan blades
    • Grounding straps and busbars
    • Heat sinks
    • Plates
    • Shields
    • Terminals and contacts

    Contact the Precision Metal Stamping Experts at Keats Manufacturing Today

    The precision metal stamping process plays a critical role in the production of components for many industries. For customers looking for an experienced and knowledgeable metal stamping partner, the Keats Manufacturing team is here to help.

    At Keats Manufacturing, we’ve provided custom small metal stamping solutions for over 60 years. Armed with extensive manufacturing experience and state-of-the-art manufacturing facilities, we can fulfill nearly every metal stamping request with a high-quality product solution. To find out more about our metalworking capabilities or partner with us on your next project, contact us or request a quote today.

     

    Frequently Asked Questions

    At Keats Manufacturing Co., we serve a wide range of industries that rely on high-volume precision components.

    • Our expertise spans automotive, appliances, electronics, and medical sectors.
    • With high-precision tolerances, we meet the specific needs of each industry.
    • Our in-house tool & die development ensures tailored solutions for your unique applications.

    Precision is at the core of our operations at Keats Manufacturing Co.

    • We utilize one of the largest fleets of four-slide machines in North America, including advanced Wünsch multi-slide machines.
    • Our commitment to tolerances of ±0.0002 in. for stamping guarantees the accuracy you require.
    • All processes adhere to ISO 9001, ISO 14001, and IATF 16949 standards for consistent quality.

    Absolutely! Keats Manufacturing Co. specializes in custom precision metal stamping. Every part we make is custom.

    • Our in-house tool & die development allows us to create bespoke designs tailored to your specifications.
    • We offer a lifetime guarantee on tooling, ensuring your investment is protected.
    • Our engineers work closely with you to optimize designs for manufacturability and cost-effectiveness.

    Lead times at Keats Manufacturing Co. can vary based on project complexity and volume.

    • Generally, we strive for efficient turnaround times, particularly for high-volume orders.
    • Lead time depends on multiple factors such as part complexity, material type, volume requirements, heat treatment and/or plating requirements. 
    • Contact us for a quote and a detailed timeline tailored to your specific project needs.

    Quality control is paramount at Keats Manufacturing Co.

    • We implement rigorous in-process inspection procedures throughout the manufacturing process to ensure compliance with high standards.
    • Our facilities are certified in ISO 9001, ISO 14001, and IATF 16949, emphasizing our commitment to quality.
    • We also accommodate other specialized quality requirements for various industries.

    Four-slide machines offer significant advantages that Keats Manufacturing Co. leverages for your projects.

    • They allow for complex shapes and high-volume production, reducing overall costs.
    • Our fleet includes advanced Wünsch multi-slide machines, enhancing precision and speed.
    • This technology enables us to achieve tighter tolerances and intricate designs efficiently.

    At Keats Manufacturing Co., compliance with industry standards is integral to our operations.

    • We are certified to  ISO 9001, ISO 14001, and IATF 16949, ensuring our processes meet rigorous quality benchmarks.
    • Regular audits and updates keep our practices aligned with evolving industry requirements.

    Keats Manufacturing Co. works with a diverse range of materials for precision metal stamping.

    • We handle various metals, including stainless steel, aluminum, copper, bronze, and brass, tailored to your project needs.
    • Our expertise ensures optimal material selection for durability and performance in applications.
    • Consult with our engineers to determine the best material choices for your specific requirements.

  3. Metal Stamping in the Automotive Sector

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    Automobiles rely on a wide range of components to operate safely and efficiently. Most of these components — which are found in every part of a vehicle, from its frame to its electrical systems — are manufactured using metal stamping and precision machining methods.

    Metal stamping, also referred to as pressing, involves placing a sheet or coil of metal into a press and forming it into the desired shape over a die or mold. This can be done in one stage or over several stages, depending on the complexity of the required end product.

    Automotive stamping allows for the manufacture of many different functioning parts, which are used in automotive bodies and frames, as well as electrical, steering, alternator, and fuel systems. These components play a crucial role in ensuring optimal safety and functionality.

    Terminals and Electrical Connectors

    The auto industry produces thousands of vehicles a year, and hundreds of terminals and electrical connectors are installed in each vehicle.

    Automotive manufacturers typically employ connectors with a two-piece socket and tab design. Using flexible materials, the male and female component ends can easily attach and disconnect, allowing for great durability and flexibility. This is crucial, given the amount of abuse these components take from weather, general wear and tear, chemical exposure, and other harsh elements cars encounter on the road.

    As the auto industry depends more and more on electrical systems, demand will rise for highly protected, durable terminals and connectors. These components can be made from a variety of different materials — including copper, brass, phosphor bronze, and various grades of steel — using four/multi-slide forming and progressive die and metal stamping techniques.

    Automotive Wire Forms

    The wire forming process involves pulling a strip of metal through a series of lubricated metal dies or molds so it can take the desired shape. Allowing for many wire sizes and shapes, this simple, versatile process can even be applied to glass. Commonly worked materials include titanium and copper, but the ideal material choice will depend on the specific application at hand.

    Wire formed products are used in a wide range of applications, including construction, which makes use of rebar, as well as heating elements and even mattresses, which make use of springs and coils. In the auto industry, wire formed products are found in tires and under chassis.

    Automotive Brackets and Hangers

    Metal brackets are also found in many different automotive applications — door panels, instrument panels, fender assemblies, and airbags, to name just a few. Primarily used to fasten one component to another, brackets can be manufactured from metals such as steel, as well as various other high-strength, oxidation-resistant alloys. Since automotive brackets may be exposed to the elements, these properties are particularly important.

    Learn More about Automotive Stamping

    Metal stamping and precision machining techniques are essential for ensuring optimal safety, reliability, and comfort in all types of vehicles. These processes, whether complex or simple, require experienced and dedicated technicians; companies should be sure to partner with knowledgeable industry leaders who can provide reliable solutions tailored to the specific application at hand. Components must be durable enough to withstand years of use in varying road and weather conditions, so quality is of utmost importance.

    At Keats Manufacturing Co., we’re proud to offer industry-leading wire form design and manufacturing services. Committed to quality in everything we do, our facilities are ISO 9001, ISO 14001 and TS 16949 compliant, and we make use of the latest technological innovations, including CAD/CAM. Our operations are overseen by 25 of the industry’s most experienced die makers.

    For more information on our custom metal stamping services for the automotive industry and discuss automotive component manufacturing options for your unique application, reach out to the team today.

  4. Keats Manufacturing Achieves IATF 16949:2016 Certification

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    Keats Manufacturing is pleased to announce that we have achieved certification under IATF 16949:2016, a technical specification for quality management systems in the automotive sector as set forth by the International Automotive Task Force (IATF).

    Precision metal stamping parts for manufacturing and industrial applications.

    What is IATF 16949:2016 certification?

    A Quality Management System (QMS) is a set of processes, policies, records, and documented procedures that lay out the internal rules under which a company produces and delivers its products and services to customers. Within the automotive industry, one of the most ubiquitous international standards for quality management is the ISO/TS 16949. This standard harmonizes the various certification systems and assessments in the world’s automotive supply chain.

    What is the significance of the certification?

    This IATF certification demonstrates a consistent commitment to customer satisfaction and quality of products and services. Both internal and external audits of our QMS documentation show that Keats Manufacturing has a high-standard Quality Management System in place and that we operate accordingly.

    What requirements must a company meet to be certified?

    IATF16949 consists of 11 sections, seven of which detail the requirements for an organization’s QMS in order to qualify for certification:

    • Section 4: Context of the organization – The organization must determine its context in terms of the QMS, including the needs and expectations of interested parties.
    • Section 5: Leadership – Top management must show leadership and commitment to implementation of the QMS as well as assign process owners and other roles and responsibilities.
    • Section 7: Support – This section details the QMS requirements for infrastructure, people, organizational knowledge, competence, communication, awareness, work environment, monitoring and measuring of resources, and documentation of information.
    • Section 8: Operation – The organization must meet product requirements in all aspects of planning and creating their product or service. This section addresses planning, review of product requirements, design, purchasing, creation of products or services, and control of the equipment for monitoring and measuring the product or service.
    • Section 9: Performance evaluation – The organization must effectively monitor the functionality of the QMS. They must assess customer satisfaction, perform internal audits, monitor products and processes, and review management.
    • Section 10: Improvement – An organization must continually improve the QMS, meeting requirements for nonconformities and corrective actions, error-proofing processes, and problem solving.

    Once the processes and procedures have been designed and implemented for a period of time, the records collected during the operation of the QMS serve as the basis for audits, reviews of the system, and, ultimately, certification.

    How is this newer version of the certification different?

    The updated version of ISO/TS 16949, IATF 16949:2016 was published on October 3rd, 2016. It replaces the previous ISO/TS 16949 and sets forth the requirements for a QMS used by an organization within the automotive industry. Meant to be used with ISO 9001:2015, it supplements the requirements for a stand-alone QMS, customizing the standard to the specifics of the automotive industry.

    IATF 16949:2016 blends various standards from across the United States and Europe. It outlines best practices for the design, development, manufacture, installation, and service of automotive products. This international measure of quality is the gold standard for any company to develop a system for ensuring improvement and customer satisfaction.

    What does the certification mean for Keats’ customers?

    We take automotive quality very seriously. The purpose of the IATF certification is to ensure that our customers can rely on faithful delivery of high-quality products. Keats Manufacturing has long been committed to customer satisfaction and ongoing improvements, and this certification is evidence of that commitment.

    To download our IATF 16949:2016 certification and our other quality certifications, click here.

  5. Metal Stamped Parts for the Automotive Industry

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    Throughout our more than 50 years of business, the engineers at Keats Manufacturing have been producing the highest quality custom metal stampings, wire forms, and assemblies for a wide range of industries. Listed below are several examples of custom metal stamped parts for automotive that Keats has manufactured.

    Positioning Sensor for Steering Wheel

    Positioning Sensor for Steering Wheel

    Keats was sent a 0.0238” thick phosphor bronze material and our engineering team was tasked with turning that raw material into terminals to be used in numerous automotive steering wheel sensors.

    Using our precision custom stamping services, Keats was able to design, build, and package one million of these terminals and ship them to the client’s location in Europe. In addition, these terminals were also plated with bright tin to increase their corrosion resistance. The reel-to-reel plating process that we performed ensured uniform deposition of the coating and significantly helped to decrease overall cost.

    Fuel Injection Steel Shield for Engines

    Fuel Injection Steel Shield for EnginesAn automotive manufacturer provided Keats with a print and a .DWG AutoCAD file that contained specifications of a fuel injection steel shield that was required for use in automotive engines.

    Using DCC programmable CMMs, our precision stamping process allowed us to manufacture one million parts from 1008/1010 cold rolled steel with tight tolerances of 0.003”. Zinc phosphate coating was then applied because of their paint bonding characteristics. We were able to complete and deliver this order with a turnaround time of 15 days.

    Terminal Wire Forms for Sensors

    Terminal Wire Forms for SensorsOne client came to Keats with a need for terminals to be used in sensors for various automotive parts. Starting with copper alloy wires with a thickness of 0.082”, the Keats engineering team leveraged our in-house AutoCAD and tooling machinery to achieve tolerances of 0.001” to manufacture 25,000 terminal wire forms with chamfered ends. The entire process, including delivery, took 30 days from start-to-finish.

    More Products for Automotive Applications

    To see where else Keats’ metal stamped products are used throughout the automotive industry, check out our interactive infographic.