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Metal stamping
Progressive die stamping
Progressive die stamping forms a part in several stations as coil strip moves through one die, so every press stroke delivers a finished part. For small parts above roughly ten thousand pieces a year, it is the lowest-cost route. We run progressive dies on 60–250 ton high-speed presses with servo coil feeders.
Key specs at a glance
| Presses | 60–250 T high-speed, coil fed |
|---|---|
| Largest bed | 2800 × 920 mm |
| Feeding | Servo feeders with straighteners |
| Strip thickness | 0.15–1.2 mm |
| Tolerance | ±0.02 mm on critical features |
| Best for | Small parts, high annual volume |
How does a progressive die work?
Coil strip is straightened and fed a fixed distance — the pitch — on each press stroke. Pilot pins locate the strip in pilot holes punched at the first station, so every station sees the strip in the same place. Each station does one job: piercing, notching, bending, forming, coining or embossing. The last station cuts the part off the carrier, or leaves it attached when parts are supplied on reel.
For you, that means low part-to-part variation and almost no handling cost, because every operation happens in one die and one setup.
Progressive die or single-hit die?
Below a few thousand parts a year, laser cutting and CNC bending usually beat both, because there is no die to pay for.
| Progressive die | Single-hit (stage) dies | |
|---|---|---|
| Tooling cost | Higher, one complex die | Lower per die, several dies |
| Unit cost | Lowest | Higher (handling between dies) |
| Part size | Small to medium | Medium to large |
| Typical volume | High annual volume | Low to medium volume |
| Supply on reel | Possible | No |
Which parts suit progressive die stamping?
- Board-level EMI shielding cans and frames
- Connector terminals, contacts and lugs, loose or on reel
- Flat spring clips, grounding fingers and battery contacts
- Small brackets, keyboard plates and mounting plates
- Small drawn cups and shells, where the draw stages fit in the die — confirmed per drawing
- Any small part from 0.15–1.2 mm strip with stable design and steady annual demand
Strip layout: where material cost is decided
The strip layout decides material cost, die length and how many stations are needed. Parts are carried on a side carrier, a center carrier or both; nesting parts at an angle or in two rows can save material on small parts. On copper alloys, where material is a large part of the unit cost, layout review often matters more than press speed.
Grain direction is set by the layout as well. If a tight bend must run across the rolling direction, say so on the drawing so the layout respects it.
How much press tonnage does a part need?
A first estimate of blanking and piercing force is the total cut length × material thickness × shear strength of the material. Forming, coining and stripper-spring forces are added on top, and a margin is left so the press does not run at its limit. Die length and the number of stations must also fit the press bed.
Our presses run from 60 to 250 tons with beds up to 2800 × 920 mm, which covers most small electronic and industrial parts in 0.15–1.2 mm strip.
Designing a part for a progressive die
- Keep holes at least about one material thickness in diameter, more for stainless
- Avoid features that must be formed after the part leaves the carrier — they need a secondary operation
- Allow small tabs or witness marks where the part is cut from the carrier
- Use bend reliefs and avoid holes close to bend lines (about 2 t plus bend radius as a rule of thumb)
- Apply ±0.02 mm only where function needs it; looser general tolerances reduce die cost and maintenance
- If parts will be supplied on reel, agree the carrier design with your assembly equipment before the die is built
Tooling, die ownership and maintenance
Our partner toolroom builds each progressive die after a design review with our engineers. Tooling cost and lead time depend on the number of stations, part size and material, and are quoted per drawing. Once the tooling invoice is paid, the die is yours; we store and maintain it at our factory for your repeat orders.
The first parts from a new die go through a full dimensional check on a vision measuring system before production is released. Production lots are inspected by AQL sampling, with automated optical inspection on critical features.
Frequently asked questions
At what volume does a progressive die pay off?
As a rule of thumb, from about ten thousand pieces a year for small parts. We check the break-even against laser cutting and bending when we quote.
How long does a progressive die take to build?
It depends on the number of stations and part complexity. Tooling lead time is confirmed per project in the quote.
Who owns the die?
You do, once the tooling invoice is paid. We keep and maintain it for your repeat orders.
What thickness can you run in a progressive die?
Our production range is 0.15–1.2 mm strip, fed from coil.
Can parts stay on the carrier strip?
Yes. Parts can be supplied on reel for automatic assembly; carrier and reel details are agreed per project.
What is the minimum order?
1,000 pieces, although progressive dies make most sense at much higher annual volumes.
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