Progressive Stamping from Westlake Tool & Die
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Progressive die stamping benefits clients via optimized production times and repeatability, making it stand out among metal forming techniques. Westlake Tool & Die has been providing quality metal parts since 1972, and our team can use our expertise in progressive metal stamping and other approaches to meet your application needs.
The Process for Progressive Die Metal Stamping
Our progressive stamping process typically begins with receiving a blueprint, which we then quote for the customer. From there, we design a tool to ensure we can consistently produce the part according to client specifications every time. This reliability is crucial for our customers, as they want their components to be repeatable, dependable, and reliable. They expect that we can produce the same part today as well as five or ten years from now, while maintaining the required tolerances.
Additionally, some customers request that we design tools with the option for future revisions. Sometimes they inform us upfront that while they have a current design, they plan to introduce a better model in the coming year, and they want us to incorporate it into the existing tool, something we’re adept at.
We will also need to determine what metals will be required by the customer. Available materials include:
- Steel
- Stainless steel
- Copper
Once we finalize the design, we begin machining all the die components in our machining center. The final steps of our progressive die stamping process involves completing the assembly of the tool, placing it in our press, and then submitting samples to the customer for approval.
How Our Progressive Tool and Die Process Stands Out
During the initial stages of a progressive die metal stamping project, we ask questions to understand the client’s expectations. For example, we may ask about the expected lifespan of a tool and if future revisions are anticipated. These questions help us determine the longevity of the part and ensure that the design meets the client’s needs.
Request A Quote
Request a quote using the form below or call us at 440-934-5305.
Request A Quote
Request a quote using the form below or call us at 440-934-5305.
We use industry-standard best practices for the stamping process, though we differentiate ourselves through features like:
- Servo-driven feed units
- Die protection
- Part-out sensors with lasers or light beams
These features enhance the efficiency and reliability of our stamping process and ensure the utmost quality for our customers. Additionally, we offer value-added services such as supply chain management and the ability to handle multiple processes. This allows us to deliver finished products to our client, minimizing their workload and streamlining their production process.
We are also ISO 9001:2015 certified and offer a range of other services, including:
Equipment and Customization
Our stamping capacity reaches up to 400 tons on our 8 presses, and our largest press has a bed size of 144 inches by 54 inches. We also have a 35-ton press, and many other presses with capacities within that range.
We design our progressive metal stamping tools to meet customer needs, including adjustability and serviceability in the press. This allows for the replacement of worn parts, like punches or die sections, without removing the entire tool. For parts that have left- and right-hand versions, we can design the tool to produce both simultaneously or to switch between the two with minimal changeover time. Our goal is to maximize efficiency by designing tools that can be easily serviced in the press.
Fields That Benefit Most from Progressive Die Stamping
As progressive die manufacturers, we’ve had the good fortune to work with a range of industries over the years. For instance, we’ve achieved significant success within the food industry, but we also serve a diverse range of other sectors, including gas exploration, power, transmission, and transportation, though we don’t specialize in automotive.
These industries are drawn to our capabilities because we can accommodate a wide range of production volumes, from around 5,000 on the low end to millions of pieces. This flexibility sets us apart from competitors who may specialize in high-volume production but neglect smaller production runs.
FAQs About Our Progressive Stamping Process
What are the typical turnaround times for progressive die stamping projects?
The timeline for building a tool can vary based on the complexity of the part and the customer’s specific needs. For instance, we’ve had cases where we built a relatively simple tool in just two to three weeks to help a customer address an urgent need, such as adding to their product line or repairing a part.
One example was when we assisted a company that sold belts to the solar industry; we quickly built a simple tool to produce a part that solved their customer’s problem. However, for complex progressive tool and die or assembly projects, the timeline can extend to 12 to 16 weeks or longer, depending on the level of complexity involved.
What are the main advantages of progressive die stamping compared to other metal forming techniques?
Progressive die stamping is significantly faster than any manual or robotic pick-and-place operation. The speed of progressive stamping ranges from several parts per second to several parts per minute.
Along with speed, repeatability is one of the prominent attributes of the progressive die stamping process. If you incorrectly position a blank into a single-hit press, you lose repeatability and dimensional integrity. Feeding a strip through a progressive stamping die via a servo-driven feed system is much more repeatable, making it far easier to maintain dimensional accuracy throughout the entire run.
Can you describe your quality control measures?
Our full, in-house quality lab handles all part testing, including dimensional layouts and hardness testing. Any additional testing is managed within our supply chain.
During tool building, we collaborate closely with customers to identify critical part dimensions or features. This information allows us to create gauges that verify these characteristics during production. Operators can then quickly check parts and halt processing to make adjustments if necessary.
By proactively addressing potential issues and ensuring part repeatability, we differentiate ourselves from competitors who may not prioritize these critical design elements. Additionally, when designing the tool, we ask upfront if there's anything essential that needs to be monitored or fail-safed, something not all organizations take the time to do.
Contact Us
In need of fast and reliable progressive stamping services? Contact the experts at Westlake Tool & Die today. We’re ready to assess your project and provide effective solutions.
