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Metal stamping is an indispensable and efficient forming process in modern manufacturing. It converts metal sheets into complex and high precision components through precise mold and high speed stamping equipment. Metal stampings has become an important driving force of industry innovation with its excellent consistency, rapid production efficiency and superior cost advantages.
As a pioneer in the industry, JS Manufacturing provides customers with customization solutions for the entire process, from material selection and mold development to mass production, with innovative stamping technology, intelligent production systems, and deep industry insights. This ensures the optimal balance of performance, reliability and economy for each metal stamping product, enabling the global high-end manufacturing sector to continue.
What is metal stamping?
Metal stamping technology is a processing method that uses metal stamper to apply mechanical pressure to flat metal sheets. It is an efficient and high-precision forming process. By using a pre designed mold shape and combining it with the downward extrusion force of a press, the metal sheet metal undergoes plastic deformation or detachment at room temperature, in order to quickly manufacture the required three-dimensional parts. The entire process involves precise metal forming, bending, cutting and other processes, suitable for manufacturing from simple to complex components.
In terms of metal stamping, the stamp metal process first involves fixing the metal sheet in place. The operator places a flat metal plate on the lower die of the mold, and the upper die (i.e. metal stamper) moves vertically downward under the drive of the press. After the upper and lower molds are closed, the cutting edge or forming structure of the mold exerts pressure on the metal, causing it to stretch, bend, or break. This process has the advantages of being able to complete multiple processes at once, significantly improving production efficiency, and is particularly suitable for mass production of precision parts.
What are the basic processes of metal stamping?
Metal stamping technique is a series of techniques to press metal sheets through metal stamps to achieve a specific shape. The following four processes reflect their refined application in the manufacture of complex parts:
1.Progressive stamping
Through multiple sets of linked metal stakes, multiple processes such as punching, bending, and forming are gradually completed on a single assembly line. JS company adopts the advanced mould technology developed by itself to achieve efficient mass production through the mould of different workstations continuously. For example, a car radiator grilles can be made by stamping step by step, bending and rotating at the same time. The precision of die connecting rod can be ±0.005mm to ensure part consistency and increase production speed by 40%.
2.Transfer mold stamping
Suitable for large or intricately shaped parts, metal billets transported between workstations by robotic arms or conveyor belts. JS servo press works seamlessly with automation systems to precisely control billet positionings. For example, in aerospace component manufacturing, a combination of transfer molding and heat treatment ensures that titanium alloy parts remain structurally stable after multiple deformations and reduce scrap rates by 60%.
3.Sliding mold stamping
Specially designed for multi angle bending, complex curve forming is achieved through horizontally sliding metal stamps. JS's flexible mold system supports online adjustment of bending angles. For example, a single stamping can complete bending in three different directions in the production of electronic component brackets, increasing material utilization by 15%. It is particularly suitable for small volume customization orders.
4.Deep Drawing
By stretching the metal stamp, metal sheets is made into a deep cavity parts. With advanced die combination and hydraulic mold combination compensation, JS's deep stretching technology can successfully form large container with diameter of 1.5m and surface smoothness ≤0.8μm, meet the strict requirements of medical devices for flawless surfaces.
What are the key steps of metal stamping process?
1.Material pretreatment and mold matching
According to the requirement of parts select metal sheets (such as aluminum, steel, copper alloy, etc.), and smooth surface by pretreatment such as leveling and cleaning. JS company uses laser measurement technology to calibrate the thickness tolerance (±0.05mm) of metal sheets for forming parameters of high-precision metal stamped mold.
2.Mold design and commissioning
Based on the 3D model of parts, the geometry and stamping path of metal stamp mold are designed, and the stress distribution of the die is optimized by CAE simulation. For example, deep drawing molds needs gradient R angle design to prevent cracking, JS's independent mold processing center can finish micrometer level edge polishing to ensure surface roughness Ra ≤0.4μm.
3.Stamping and forming stage
Placing the metal plate on the press table, plastic deformation is accomplished through the collaboration of metal stamp mold and hydraulic/servo press. For example, the progressive gap design of the die during tensile process can control material flow and prevent wrinkling or cracking, and JS's real-time pressure feedback system can dynamically adjust the edge pressure to increase yield rate to 99.2%.
4.Post-treatment and surface optimization
Metal stamped products are trimmed, rimmed or electrolytic polishing to remove burrs and improve finish. JS's automated deburring equipment can handle tiny parts up to 0.1mm in size, combines PVD coating technology to improve the corrosion resistance of parts and meet high durability requirements such as car battery casing.
5.Quality inspection and data closure
Dimensional accuracy of metal stamp parts (e.g. hole spacing ≤0.01mm) was verified using CMM or optical scanning, and mold parameters and production data were tracked through the MES system. JS's AI visual inspection system can identify 0.02mm level defects real time, ensuring batch consistency.
What are the types of metal stamping molds?
Metallic stamping molds is the core tool of manufacturing industry. It is mainly divided into the following categories:
1.Classified by process type
Punching mold: Used to separate metal sheets, complete the cutting, punching, cutting and other procedures to obtain the required contours or holes. The core of the die is the combination of concave die and concave die. The precision of die clearance determines the quality of die section. Widely used in the production of hardware and electronic components.
Bend mold: Bend metal plate at a specific angle or shape (e.g. U-shape, V-shape) and complete the bending by a combination of pressurized convex and concave die, taking into account rebound compensation.
Deepening mold: Stretching flat billets into hollow three-dimensional parts (such as cups or cylinders) by convex pressing concave molds requires control of wrinkling and cracking. Suitable for the production of artillery shells, tanks, etc.
Forming mold: Used for local plastic deformation of metal sheets, such as bulging, ripping, and constriction of neck, through which material is stretched or compressed to a specific shape, suitable for processing complex curved surfaces or reinforced steel structures.
Composite mold: It completes several stepssuch as stamping, cutting, molding and so on in a single stamping stamping, and realizes efficient machining through the combination of convex die structure. Suitable for mass production of small and medium sized parts with high precision and multi-process.
Enter mold (continuous mold): Through several continuous stamping, stamping, bending, forming and so on the strip material, the final efficient cutting of the the finished product, suitable for large-scale production of small precision parts.
2.Classified by mold structure
- Single track mold: Only one stamping (such as stamping or cutting), simple structure, low cost, suitable for small batch production or simple parts processing.
- Combination mold:
Composite mold: Multiple processes (such as cutting and stretching) at the same workstation.
Progressive mold: Continuous processing (stamping → bending → cutting) in different working positions.
- Transfer mold: used for the transfer of blank of multiple presses and robotic arm, suitable for large parts such as automobile overlay.
How to prevent tearing during stamping of ultra-thin metal sheet(<0.1mm)?
According to the characteristics of stamping on metal process, the key techniques and measures of stamping and tearing prevention of ultrathin metal plates (<0.1mm) are introduced below:
| Type of technology | Core principles | Specific measures | Applicable scenarios | Anti-tear effect |
| Mold optimization | Reduce stress concentration. | Gradient R-angle mold + progressive stamping. | Precision stamping (such as sensor housing). | Tear risk ↓ 40%. |
| Material selection | Increases scalability. | Aluminum foil/annealed stainless steel. | Large deformation molding (such as battery housing). | Fracture toughness increased by 25%. |
| Process control | Optimize pressure and speed. | Servo press+low-speed stamping. | High-speed continuous production. | The yield rate increased by 35%. |
| Lubrication treatment | Reduce frictional resistance. | Waterborne lubricant+DLC coating. | High speed precision stamping. | Surface scratches ↓ 90%. |
| Flexible mold | Buffer pressure fluctuations. | Polyurethane soft mold+air cushion assistance. | Thin-walled composite components (such as microscaffolds). | Tear rate ↓ 50%. |
Stamping on metal compatibility:
- Ultra thin metal stamping requires flexibility of die and dynamic adjustment of process parameters (e.g. real-time feedback from servo presses).
- Flexible molds,such as polyurethane, absorb local stresses during material flow and avoid hard contact tearing.
- Technology synergy:
Mold optimization+lubrication treatment: Reduce material flow resistance and mold adhesion, suitable for soft materials such as aluminum foil.
Step-stamping + flexible die: Phased deformation reduces single load, suitable for mass production of ultra-thin battery housing.
What type of process is required for titanium alloy stamping?
Titanium alloy stamping requires hot stamping or hot stamping combined with high-precision CNC machining and special mold technology. The specific reasons are as follows:
1.High temperature plasticity improvement
Titanium alloy have high hardness and resistance to deformation and are prone to cracking when pressed at room temperature. By heating the material to 600-850℃ (hot stamping) or 300-500℃ (warm stamping), the plasticity of the material can be greatly improved, forming difficulty reduced and the rebound minimized.
2.Precision CNC auxiliary processing
Combined with JS company's ±0.005mm high-precision CNC equipment, titanium alloy parts can be pressed for precision polishing at the micrometer level to meet stringent tolerance requirements in aerospace, medical, and other fields.
3.Special molds and lubrication technology
Adopt high temperature resistant mold materials(such as tungsten steel or ceramic coated mold), combine nitrogen or graphite lubricants, prevent mold wear and titanium alloy bond, prolong mold life.
4.Surface treatment matching
After stamping, titanium alloys needs to be anodized, sandblasted or chemically passivated to improve its corrosion resistance and appearance. It is also an extension JS company's material processing technology.
How to deal with zero gravity environment in space metal stamping?
1.Material fixation technology in microgravity environment
Electromagnetic adsorption and vacuum clamping are used to overcome the limitation of traditional mechanical fixation.JS's automation system adjusts the clamping force in real time, ensuring the metal retains a positioning accuracy of 0.02mm even in weightlessness. The tolerance control of the numerical control equipment reaches ±0.005mm, which satisfies the strict requirement for the precision of spacecraft docking mechanisms.
2.Intelligent flow reconstruction
Through the cooperative operation of industrial robot clusters, JS detects micro-scale displacement by gravity-free compensation algorithm and realizes automatic adjustment of stamping parameters. Its adaptive control system can control the machining error rate to less than 0.3%. The technology has been demonstrated in the production of satellite solar panel supports, with a 40% increase in productivity.
3.Improving adaptability to vacuum-environment processes
The inert gas shielding arc cladding technology used to solve the problem of metal oxidation in vacuum. JS laboratory data show that 15μm of dense oxide film is formed on the surface of titanium alloy surface treated by this process.
4.Optimization of lightweight structural design
Based on 3D printing additive manufacturing technology, JS can achieve integrated topology optimized structures. A case study of a certain type of rocket fuel nozzle shows that through lattice structure design, the weight is reduced by 45%, the pressure bearing capacity reaches 1.8 times that of traditional technology, and the space load requirement is perfectly balanced.
5.Extreme environment simulation verification system
A comprehensive testing platform consisting of vacuum chamber, centrifuges and thermal shock chamber was established, capable of simulating temperature gradients ranging from -180°C to +300°C and 10^-6Pa degree. In vacuum environment, the fatigue life of the validated product increased to more than 5 times the ground condition.
What are the common surface treatment methods for aluminum stamping?
1.Anodizing
- Function: To improve hardness, corrosion resistance and abrasion resistance by electrolysis and forming oxide film on aluminum surface.
- Commonly used in stamping metal forming parts (such as automobile chassis parts, 3C product shells, etc.), the oxide film thickness can reach 15-50μm, which can significantly improve the scratch resistance of the surface.
2.Electroplating
- Function: Coating aluminum surface with metal layers (e.g. nickel, chromium, zinc) to improve conductivity, reflectivity or rust resistance.
- Before plating, the stamp metal needs to be pickled and activated to ensure the adhesion of the coating. nickel plating treatment, for example, can improve the life of plugs and sockets in electronic connector components.
3.Spraying
- Features: Color customization and corrosion protection through electrostatic spraying or fluorocarbon coating.
- Suitable for complex stamping metal surfaces (such as home appliance and lighting fixtures), phosphorylation is required prior to spraying to enhance coating adhesion, which can be 60-120μm film thickness.
4.Chromate Conversion Coating
- Function: To form a passivation film by chromate solution, prevent rust and improve welding performance.
- Used in stamp metal welding (such as car battery trays), the thickness of the film is about 1-3μm, which takes into account environmental protection and corrosion resistance.
5.Polishing/Brushing
- Function: Mechanical or chemical polishing eliminates stamping marks and improves surface smoothness.
- Mirror mirror polishing (Ra ≤0.1μm) meets the requirements of optical devices for stamping metal molds such as aluminum heat sinks.
What are the technological advantages of JS company in the field of metal stamping?
1.Ultra-high precision machining: With advanced CNC technology (such as CNC), tolerance of ±0.005mm can be achieved to meet the requirements of precision parts.
2.Multi material adaptation: Supports stamping of materials such as metals and composites and has processed more than 50 materials in the past year.
3.Process efficiency: 98% of orders are delivered on time, project cycles are reduced by an average of 15%, and stamping lead times are optimized.
4.Cost control: Reduce production cost by 20% and improve resource utilization through process optimization.
5.Green manufacturing: Reduce energy energy consumption and waste by 20% using energy-efficient equipment and material recycling systems.
Summary
In the metal stamping industry, the performance of metal stamp is closely related to the accuracy and quality of the final product, and to achieve this goal, it must rely on high-precision pre-processing technology. Through steps such as surface cleaning, deburring, annealing, and surface modification (such as phosphating and lubricating coatings), not only can the ductility of metal materials be significantly improved and the risk of cracking or oxidation during stamping be reduced, but it can also lay a solid foundation for subsequent metal stamping operations.
JS combines high-precision CNC machining technology with environmentally friendly processes, incorporating the concept of sustainable development into the pre-processing stage, ensuring that metal stamping parts can maintain consistency whether they are structurally complex or mass-produced. This full process optimization from material preparation to finished product delivery not only improves production efficiency (reducing project cycle by 15%), but also promotes the industry's transformation towards high efficiency, low consumption, and high added value through technological innovation.
Disclaimer
The content on this page is for general reference only. JS Series makes no express or implied warranties regarding the accuracy, timeliness, or applicability of the information provided. Users should not assume that the product specifications, technical parameters, performance indicators, or quality commitments of third-party suppliers are completely consistent with the content displayed on this platform. The specific design feature, material standards, and process requirements of the product should be based on the actual order agreement. It is recommended that the purchaser proactively request a formal quotation and verify product details before the transaction. For further confirmation, please contact our customer service team for professional support.
JS Team
JS is an industry leading provider of customized manufacturing services, dedicated to providing customers with high-precision and high-efficiency one-stop manufacturing solutions. With over 20 years of industry experience, we have successfully provided professional CNC machining, sheet metal manufacturing, 3D printing, injection molding, metal stamping and other services to more than 5000 enterprises, covering multiple fields such as aerospace, medical, automotive, electronics, etc.
We have a modern factory certified with ISO 9001:2015, equipped with over 100 advanced five axis machining centers to ensure that every product meets the highest quality standards. Our service network covers over 150 countries worldwide, providing 24-hour rapid response for both small-scale trial production and large-scale production, ensuring efficient progress of your project.
Choosing JS Team means choosing manufacturing partners with excellent quality, precise delivery, and trustworthiness.
For more information, please visit the official website: jsrpm.com
FAQs
1.What is the difference between stamping and casting?
Stamping is a cold machining process in which metal plates is pressed into shape by die. It is high efficiency andprecision and is suitable for thin plate parts. Casting is a thermal process in which molten metal is poured into molds to form complex shapes, but with low precision.
2.How important are molds to stamping?
Mold is the core tool of stamping, which determines the shape, precision and efficiency of parts. Without the die, stamping is impossible, its design directly affects the product pass rate and production cost, is the soul of stamping technology.
3.What should be paid attention to when stamping stainless steel?
Stainless steel stamping requires the use of high-hardness die, control stamping speed, stamping with lubricating oil, and annealing in time to eliminate hardening of workpiece, to avoid cracking and excessive mold wear.
4.What thickness of metal is required for stamping automotive parts?
The thickness of the sheet metal commonly used for stamping automobile parts is 0.6-2.5mm. Body coverings (such as car doors) are mainly made of 0.6-1.2mm ordinary steel plates, while structural components (such as collision beams) are made of 1.2-2.5mm high strength steel with balanced strength and molding.
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