Progressive Die Stamping

Progressive die stamping produces complex sheet metal parts from coil in one continuous operation, ideal for high-volume runs with consistent features and low per-part cost.

Overview

Progressive die stamping uses a series of stations within one tool to pierce, form, coin, and cut parts from coil stock in a continuous feed. Each press stroke advances the strip and adds features, so the finished part exits the die every hit. This delivers very high throughput, consistent quality, and low per-part cost once tooling is built.

Choose progressive stamping for thin sheet metal parts with multiple features, where annual volumes justify a dedicated die—typically tens of thousands to millions of pieces. It excels at terminals, brackets, and small to medium components that fit within standard press beds. Tradeoffs: high upfront tooling cost, longer die-build lead time, limited ability to handle very deep draws, thick sections, or frequent design changes. Feature geometry must align with strip progression and material flow, and extremely tight flatness, burr, or cosmetic requirements can drive more complex tooling and higher maintenance needs.

Common Materials

  • Low carbon steel
  • Stainless steel 304
  • Aluminum 5052
  • Copper C110
  • Brass C260
  • Phosphor bronze

Tolerances

±0.001" to ±0.003"

Applications

  • Electrical connectors and terminals
  • Lead frames and contact springs
  • Small brackets and clips
  • EMI/RFI shield cans and covers
  • Battery contacts and busbars
  • Appliance and automotive small stampings

When to Choose Progressive Die Stamping

Use progressive die stamping for thin sheet metal parts with repeatable geometry and volumes high enough to absorb tooling cost. Best for small to medium parts that need multiple pierce, form, and cut operations in one pass. Ideal when you care about very low piece price, consistent quality, and long production runs from coil.

vs Transfer Die Stamping

Choose progressive die stamping when parts can remain attached to the strip and be completed through sequential in-die stations, enabling faster cycle times and lower part handling. Transfer dies make more sense for larger parts or those needing operations that can’t be supported by a carrier strip, but they are usually slower and less efficient at very high volumes.

vs Deep Drawing

Use progressive die stamping when parts are relatively shallow forms, flanges, pierces, and simple bends instead of tall cups or can-like geometries. Deep drawing is better for high depth-to-diameter ratios, while progressive tools can integrate limited draw stages with other features for faster, cheaper production on shallow or moderately drawn parts.

vs Blanking & Piercing

Progressive dies are better when you need multiple operations—blanking, piercing, forming, and cutoff—combined into one continuous tool for high volume. Standalone blanking and piercing suits simpler parts, prototypes, or lower volumes, but separate operations add handling, alignment error, and labor that progressive stamping eliminates once tooling is justified.

vs Coining

Coining is a localized secondary operation for very tight thickness, flatness, or feature definition, often used on thicker sections. Progressive stamping is the better choice when you need overall part geometry, pierces, and bends produced in one high-speed pass, and only moderate edge conditioning or feature refinement is required; coining can be integrated into a progressive die if small coined features are needed.

Design Considerations

  • Keep material thickness and alloy consistent across the life of the tool; changes in hardness or thickness can break punches and upset clearances.
  • Work with the stamper early on strip layout, carrier tabs, and feed direction so all features can be formed while the part is still well supported.
  • Size holes and slots to be at least 1.2–1.5× material thickness in diameter/width to avoid punch breakage and excessive burrs.
  • Use generous internal corner radii (≥ material thickness where possible) on bends and cutouts to improve tool life and reduce cracking.
  • Maintain adequate webs and edge distances between features (often ≥2× material thickness) to keep the strip strong during progression.
  • Define a clear datum scheme and realistic flatness/burr requirements; over-constraining these can force expensive secondary operations or complex die stations.