Stamping

Stamping forms sheet metal into repeatable parts using hardened dies and presses, delivering fast cycle times, low unit cost, and consistent features at volume.

Overview

Stamping is a sheet-metal forming process that uses a press and matched dies to cut and shape coils or blanks into finished parts. Common operations include blanking and piercing, progressive and transfer die stamping, deep drawing for cup-like shapes, and coining for sharp details and controlled thickness.

Choose stamping when you need high volumes of metal parts with consistent geometry, fast takt time, and low piece price after tooling. It works best for parts that start as uniform sheet and can be made in one or multiple die stations with manageable forming strain.

Tradeoffs: upfront die cost and lead time are significant, and design changes can be expensive. Geometry is constrained by sheet thickness, bend radii, draw depth, and springback. Expect burr direction, edge rollover, and cosmetic tool marks unless specified; secondary ops (deburr, plating, tapping, welding) are common.

Common Materials

  • Low-carbon steel
  • Stainless steel 304
  • Aluminum 5052
  • Aluminum 6061
  • Copper
  • Brass

Tolerances

±0.002" to ±0.005"

Applications

  • Electrical connector terminals
  • Automotive brackets and clips
  • Appliance panels and housings
  • Shielding cans and RF covers
  • Deep-drawn cans and cups
  • Nameplates and tags

When to Choose Stamping

Stamping fits high-volume production where tooling investment is justified and repeatability matters. It’s a strong choice for parts made from uniform sheet thickness with features achievable via punching, bending, coining, or drawing. Plan for production intent early so die design, coil yield, and secondary ops are optimized.

vs Forging

Choose stamping when the part can be made from sheet and you need thin-wall geometry, pierced features, and very high throughput. Stamping typically delivers lower unit cost at volume and easier incorporation of holes/slots than solid-state deformation of thick stock.

vs Extrusion

Choose stamping when the part is primarily planar or shallow-formed and needs cutouts, embossments, or multiple discrete features per hit. Extrusion is better for long constant cross-sections, while stamping excels at netting complex 2D profiles and formed tabs from sheet.

vs Wire Forming

Choose stamping when you need flat features, controlled edges, and multi-feature parts from strip (holes, slots, coined details). Wire forming is well-suited to spring-like 3D shapes from round wire, but it can’t produce broad planar surfaces or punched apertures.

Design Considerations

  • Hold consistent material thickness; avoid local thick-to-thin transitions that require machining or special forming
  • Use inside bend radii appropriate to thickness and material to reduce cracking and die wear
  • Orient critical holes and slots relative to grain direction and bend lines to control cracking and dimensional shift
  • Specify burr direction and allowable edge condition (break edge, deburr level) so quoting includes the right secondary ops
  • Allow clearance for punches and add reliefs at bend ends to prevent tearing and distorted flanges
  • Dimension to functional datums achievable in-sheet; expect springback and avoid over-constraining formed angles without adjustment features