Tag Archive: progressive die stamping

  1. The Difference Between Multi-Slide and Progressive Die Stamping

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    Various manufacturing processes require the use of precision metal-stamped products made from slit coil steel, copper, and brass, among other materials. These products are manufactured using power press stamping machines specifically built to produce parts from coiled metal or another similar materials.

    There is more than one type of stamping machine. The first is the progressive die stamping machine, which allows operations on a piece of metal until a final component is produced. This type of machine combines an automatic feeding system with punching, coining, bending, and other processes for modifying metal raw material and turning it into finished products.

    Another type of stamping machine is four-slide/multi-slide stamping machine, which makes possible the production of shapes and bends of varying complexities. This type of machine is used in the mass production of stamped components made from bar or wire stock.

    Progressive Die Stamping

    Progressive die stamping machines utilize a vertical motion when processing slit coil metal. Bending and cutting operations are performed simultaneously within a die to complete at least one part with every stroke of a machine. The coiled material is fed through the die and is processed progressively in steps.  Progressive die tooling can have as little as one step or as many as 40 steps depending on the complexity of the part.  Because of the nature of the process which requires material to be pushed into the next station with every stroke of the tool, a progressive die must pilot material in order to locate it within the die prior to cutting and forming.  The requirement of pilot holes within the progressive material strip can sometimes lead to excessive scrap or waste within the process.

    However, progressive die machines take 38% less time to set up than four-slide or multi-slide machines.  This can allow manufacturers to produce smaller lot sizes and be more flexible with production scheduling to produce only what the customer needs when they need it.  The principles pioneered by legendary Japanese manufacturing engineer Shigeo Shingo: SMED (Single Minute Exchange of Dies) can be applied to progressive die machines and is standard practice at Keats.  Progressive dies are also capable of producing more than one part per stroke, making them ideal for manufacturing high volume:

    • Terminals
    • Brackets
    • Lead frames
    • Busbars
    • Shields

    Four-Slide/Multi-Slide Stamping

    As the name suggests, four-slide metal stamping machines have four moving slides. In contrast, multi-slide stamping machines may have more than four moving slides. Four-slide or multi-slide metal stamping works horizontally based on right angles, with the slides (rams) in the machine striking the coil material to produce the finished product.

    The production of complex bends and shapes is made possible by the servo motors or mechanically actuated cams acting on the slides. With this type of machine, adding threading, screwing insertion, staking, and other value-added assembly operations are possible.

    Four-slide and multi-slide stamping produces 31% less scrap on average when compared to progressive die stamping.  This is made possible by removing the requirement of pilot holes and replacing piloting operations with slotted blank holders which allow the part to move from the punching to forming operations without the need for pilots.  This also allows Keats to purchase raw material to the exact width of the part and eliminate trimming.  Since Four-slide production allows use of an infinite number of planes and axes, it can produce a maximum of 375 parts per minute, making it ideal for mass production of highly-complex parts such as:

    • Clips
    • Clamps
    • Fasteners
    • Bushings
    • Jaws
    • Yokes

    For context, 96% of all clips made at Keats are made using multi-slide die stamping.

    Because multi-slide machines are much more complex, they can take longer to setup than progressive die machines.  Four-slide production is ideal for components with high volume requirements where material cost and scrap are large contribution factors to the cost of the component.

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    They may be different, but multi-slide stamping and progressive die stamping each have their own set of advantages. Whatever stamping method is right for your needs, you can be sure Keats Manufacturing Company has the capabilities to provide it for you. We perform a detailed analysis of every RFQ and provide our customers with the most cost effective production solution.

    Keats has been providing custom metal stamping, assemblies, and wire forms for 60 years, and our facilities contain nearly 150 metal stamping and wire forming machines that operate 24 hours a day, 5 days a week. We provide everything from custom prototyping to high-volume orders containing 100’s of millions of parts.

    To learn more about our metal stamping processes or other services, contact us or request a quote.

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    The Difference Between Multi-Slide and Progressive Die Stamping

  2. 10 Steps to Convert Machined Prototypes to Progressive Die Stamped Parts

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    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.