Progressive Die - The Advanced Level of Metal Stamping

What Is Progressive Die Stamping?

Progressive die stamping is one of the methods of the metal stamping process where, through stamping press strokes, a flat strip from a steel coil is transformed into complex parts. The flat strips, via an automatic feeding system, pass through a series of stations within a single tool called a progressive die. Each station performs a specific operation, such as blanking, chamfering, piercing, bending, rounding, or even deep drawing, progressively shaping the metal into the desired shape or forming the required feature. Progressive die stamping is highly efficient for mass production, given its ability to perform multiple operations into a single process, exponentially reducing production time and costs.

 

 

 

What Is A Progressive Die?

A progressive die is a complex, multi-station tool used in progressive die stamping. It is designed to transform a flat metal strip into intricate parts. As the strip is fed into the stamping press, it continuously moves through various stations of the tool. Typically, each station performs a distinct operation—such as blanking, chamfering, piercing, bending, rounding, or even deep drawing. With each press stroke, multiple operations occur simultaneously, making the progressive die highly efficient. This process is analogous to an assembly line, where each station focuses on a single task, but collectively, they transform the strip into a finished product, enhancing overall efficiency.

 

 

What Is the Difference Between a Progressive Die and Other Metal Stamping Dies?

1. A simple die features just one station and performs a single operation per stroke, such as cutting, bending, or piercing, making it a single-purpose tool. 

2. It is suitable for parts of low complexity. While multiple simple dies can be used sequentially to shape a part, using too many can significantly reduce efficiency. 

3. It is recommended for low-volume production and are particularly effective for straightforward designs. They are generally less expensive and simpler to manufacture compared to compound or multi-station dies.

A progressive die stands out from a simple die in several key ways: 

1. It incorporates multiple stations, each designed to perform distinct operations. This setup allows for the production of more complex parts with high precision and efficiency. In contrast, simple dies execute a single operation per press stroke. Progressive dies, however, can perform multiple operations simultaneously during each stroke, facilitated by an advanced material feeding system.

2. Progressive die stamping is particularly advantageous for projects that involve complex designs and require large quantities or mass production.

 

 

What Is the Difference Between Progressive Die and Compound Dies?

1. A compound die features only one station but performs multiple cutting operations. If this die also includes other operations like bending, drawing, and chamfering in a single station, it is referred to as a combination die. Despite being a multi-purpose tool, its application is quite limited due to the restricted number of operations it can perform, making progressive stamping generally more efficient for most designs.
2. It is typically used for producing low-complexity, flat parts such as washers.
3. It requires a high punch force to operate.
4. It maintains a high production rate.

A progressive die differs from a compound die on the following aspects:

1. It consists of multiple stations, each performing different operations during the same stroke, achieving similar production efficiency to compound dies but with advantages like shorter testing and tool setup times, as well as reduced maintenance and repair requirements. 

2. Progressive dies can create more complex shapes due to the numerous stations and operations that can be incorporated within the same tool. 

3. Generally, progressive dies operate faster than compound dies by reducing material handling costs, thus making them more suitable for mass production. 

4. Operations in a progressive die are carried out at different stations; for instance, while a compound die might perform blanking and piercing in one station, a progressive die would handle these tasks at separate stations, improving both efficiency and the quality of the final product.

 

What Is the Difference Between Progressive Die and Transfer Die?

Transfer dies share similarities with progressive dies but are distinct in several ways: 

1. Transfer dies are multi-stage stamping tools; however, unlike in progressive dies where a part advances progressively through a series of stations while remaining connected to a strip, in transfer dies, the part (or blank) moves from one station to another between each stroke. 
2. These dies support intricate designs and are particularly suitable for deep drawing operations. 
3. They require a complex transfer and lifting mechanism to function, which can complicate their design.

On the other hand, progressive dies differ from transfer dies in these critical areas: 

1. In progressive dies, the part remains attached to a strip until the final operation, whereas in transfer dies, the blank is cut out during the first operation. This difference can lead to more scrap material in progressive dies due to the space needed for the strip, but it also allows for quicker operations with less movement required between strokes. 
2. Progressive dies have some limitations with deep drawing operations, which transfer dies can better accommodate, as they allow extensive drawing depending on the raw material's limits. Layana’s engineering team is available to help determine whether a progressive or a transfer die would be more effective for your mass-production needs.

 

 

Is Progressive Die Right Choice for Your Project? Let's Explore!

At Layana Company, a leading manufacturer certified in IATF 16949, ISO 50001, and ISO 14064 and based in Taiwan, we bring over four decades of expertise to the table. Our experience in designing, developing, and integrating progressive dies into mass production ensures we deliver high-quality, secure, and customized stamping services to top-tier global OEM manufacturers.

 

Why Choose Layana?

1. Our comprehensive services, including stamping, plastic injection (featuring insert molding), and assembly, position us as a pivotal collaborator for your most challenging projects. With Layana, you gain access to an integrated quality management system that aligns with the highest industry standards, offering total quality management throughout all manufacturing stages.
2. Engineering Excellence and ESG Commitment: Our skilled engineering team is ready to assist you in designing and developing progressive dies that not only meet but exceed your project's demands. We focus on maximizing production efficiency, ensuring your project's success. By partnering with Layana, you also advance your Environmental, Social, and Governance (ESG) goals. Our Green Factory certification is a testament to our commitment to sustainable, ethical, and environmentally responsible manufacturing processes.

 

Comparison Between Stamping Dies: Simple vs. Compound vs. Progressive vs. Transfer Dies

 

  

What Are the Advantages of Progressive Dies?

• Increased Efficiency: Progressive dies excel in their ability to perform multiple operations in a single pass through the press. This multi-tasking capability significantly speeds up production, enabling the manufacture of thousands of parts per hour. This efficiency is critical in high-volume production environments where time and speed are of the essence.

• Cost-Effectiveness: Although the initial setup cost for progressive dies can be higher, the long-term savings are substantial. The continuous nature of the process reduces labor costs and increases throughput, making it a cost-effective solution for large runs. Moreover, the precision of progressive dies minimizes material waste, further driving down costs.

• Enhanced Precision and Consistency: Progressive dies are renowned for their ability to produce parts with high precision and uniformity. Each station within the die is designed to perform a specific operation precisely, ensuring that every part produced is consistent with the next. This is particularly advantageous for industries requiring tight tolerances and high-quality standards, such as automotive and aerospace.

• Reduced Labor Requirements: Since the progressive die stamping process is highly automated, it requires fewer operators. This not only reduces labor costs but also decreases the potential for human error, enhancing the overall quality of the production.

• Versatility: Progressive dies can handle a variety of materials and can be designed to perform a wide range of operations—from cutting and punching to bending and coining. This versatility makes them suitable for producing complex components used in various industries.

• Scalability: Progressive dies are scalable to meet increasing production demands. Once the die is designed and created, scaling up production is a matter of running the die for longer periods, making it easy to respond to higher demand without significant additional costs.

• Improved Safety: The automated nature of progressive die stamping reduces the chance of operator injury, which is especially important in fast-moving production environments. The machines are designed with safety in mind, limiting operator interaction with the press during operation.

• Longevity: Progressive dies are built to last. With proper maintenance, they can operate for millions of cycles, making them a durable investment for continuous, long-term use.

 

What Are the Disadvantages of Progressive Dies?

• Not suitable for low quantities: Progressive dies require high tooling design, development, and manufacturing cost, which are easily amortizable for large quantities, but for very low quantities other metal forming methods might be considered.

• Not suitable for all designs: If the parts cannot be formed from metal blanks, because the part is too big, too thick, has undercuts, very sharp angles and tight bends, or other internal features, stamping won't be able to achieve them. Other metal forming methods such as CNC machining, casting, forging, rolling, or extrusion might be considered. Layana engineers can help to evaluate the manufacturability of your design and propose the best solution for you.

• Not suitable for prototype development: giving the upfront tooling cost, and die design and manufacturing requirements, the need of supplementary forming methods might be considered for making prototypes, such as 3D printing or CNC machining.

• Strength requirements: for some applications where exceptional strength is required, other forming methods that imply grain structure reinforcement might be required, such as forging.

• Not suitable for designs with some specific deep drawn requirements: Even progressive dies allow deep draw, for some designs or if the drawing is too deep, transfer dies might be considered.

• The die design and manufacturing complexity: Progressive dies are very complex and require a professional, dedicated engineering team with many years of experience. Layana Company has an engineering team, with engineers with decades of experience in the design and fabrication of progressive dies.

 

Elements Required for Progressive Die Stamping

To produce parts through progressive die stamping, several critical components are necessary:

1. A Progressive Die: Designing and producing high-quality, durable, and reliable progressive dies is a capability not all companies possess. Layana Company, however, boasts decades of experience in crafting progressive dies used by world-class OEM manufacturers across various industries, including Automotive, Electronics, Medical, and Aerospace.
   
   
2. A Stamping Press: Layana houses a range of stamping presses with capacities from 25T to 300T. These presses enable us to offer metal stamping mass production services to a global clientele, primarily using progressive dies that are designed and developed in-house.
   
   
3. A Feeding System: This is a crucial component in progressive die stamping. The feeding system must provide smooth and consistent material flow, ensuring precise positioning and speed across the different stations of the progressive die. Essential features of this system include:
     1.    Uncoiling and Flattening System: Necessary for preparing the raw material for entry into the progressive die, this system unrolls and flattens the metal strip.
     2.    Collector System: Positioned at the end of the feeding line, this system gathers the leftover metal strip material after the final blanking operation. The collected scrap can then be re-coiled and recycled.
   
   
4. Raw Material: Typically, the raw material used in progressive die stamping is a metal coil that is unrolled, flattened, and fed into the stamping press. The choice of material is critical and depends on the design and engineering requirements of the part, considering factors such as ductility, hardness, electrical conductivity, and cost. Common materials include stainless and carbon steel, ferrous alloys, aluminum, brass, bronze, copper, beryllium copper, and titanium.
   
   
5. Skilled Operators: Progressive die stamping is a sophisticated metal forming technique that demands well-trained and experienced operators. These professionals are essential for minimizing downtime, optimizing production efficiency, ensuring quality, maintaining safety, and performing periodic maintenance. Layana Company ensures that all operators are highly skilled, bringing years of industry experience and a commitment to continuous improvement. Notably, Layana was recognized with the Green Factory label in 2022, affirming its commitment to the highest ethical standards and working conditions for its operators.
   
   
6. Quality Management: A dedicated quality lab and a quality assurance department are crucial to control the quality of stamped parts and ensure compliance with the stringent protocols and standards required in industries like automotive. Layana Company not only offers tooling design and progressive die stamping production services but also implements comprehensive quality management throughout the manufacturing process, meeting the rigorous standards of the electronics and automotive industries.
   
   
7. Professional Engineering Team: The success in metal stamping significantly depends on the quality of the engineering team. Layana's engineers are adept at designing high-quality and precise dies, integrating the latest technology, and providing solutions for challenges that arise during the design, development, and production stages. With four decades of experience, the Layana engineering team has established a reputation for designing progressive tooling that meets world-class standards and achieves efficient, sustainable production for parts used in leading global OEM companies.

 

 

 

Progressive Die Stamping Process and Key Components of A Progressive Die

Here is an overview of the process and the essential operations involved in progressive die stamping:

Feeding System and Pilot Holes: The process begins with the feeding system delivering the flattened metal strip into the progressive die within the press. Accurate positioning of the strip is crucial for precision in subsequent operations. To achieve this, pilot holes are initially pierced in the strip at the first station. These holes guide the strip precisely through subsequent stations, ensuring it is perfectly aligned for each stroke of the machine.

Operations in Progressive Die Stamping:

1. Piercing or Punching: This involves creating holes in the metal strip.
2. Blanking: This process cuts out pieces of the raw material to shape the final part.
3. Coining: This operation uses pressure to create specific surfaces or features on the part.
4. Chamfering: This involves cutting the edges of a part at a 45-degree angle to remove sharp 90-degree edges.
5. Bending: This process transforms a flat material into a three-dimensional shape.
6. Embossing: This technique creates raised or recessed designs on the metal surface, often for aesthetic purposes.
7. Drawing: This is the process of stretching sheet metal into a U-shaped cavity to form the part.
8. Deep Drawing: A specialized form of drawing used when the height of the part is equal to or greater than half its diameter.

 

Some of these processes can be observed in the diagram below, with a metal strip resulting from different progressive die operations:

 

Progressive dies differ from other stamping dies of less complexity on the use of modules to increase efficiency of design, maintenance and installation efficiency, the level of complexity because of the multi-station nature, the use of pilots to alight the metal strip, or the stripper plate so that the scrap will not be raised with the male die.

 

Below there is a diagram with some of the different parts that are common to most of the progressive dies, but keep in mind that the components observed in a die might vary between dies given its complexity, the different design possibilities, the almost infinite possibility of shapes that can be created, the nature of project, among other factors.

 

 

 

Layana's Progressive Die Capabilities

 

The Applications of the Progressive Dies

Progressive dies enable the stamping of a great variety of parts and components that will be later used as finish parts, assembled in other products, or embedded in plastic using plastic insert molding techniques and creating more complex parts. Metal stamping, and specifically the progressive die stamping, is widely used in the automotive, biking, aerospace, medical equipment, optical, electronics industries, or even it can be used to make cutlery products.

 

Products such as home appliances or electronics components commonly used progressive die stamped components, for instance the springs, lead frames, connectors, contactors, covers, sensors terminals, pins and contacts, cages or even the USB ports. Many components from the PCBs are also made using progressive die stamping or microstamping.

 

For the automotive industry, apart from the terminals and connectors previously mentioned, and many times inserted into plastic using insert molding, one of the Layana’s specialties, many kinds of brackets, washers, spacers, plates, clutches, valves retainers, protective housing or shields, fasteners, or even trim and cosmetic parts are manufactured massively, securely, and effectively thanks to the progressive dies.

 

Apart from the mentioned industries, the possibilities are almost infinite and recently, we have seen the incorporation of progressive die stamped parts into new products such as drones, solar panels, electric car chargers, etc.