Micro Stamping
What is Microstamping?
Microstamping, also known as precision stamping or micro forming, refers to the production of miniature parts characterized with micro features. Microstamping is similar to metal stamping, with down-sized operations called micro-blanking, micro-bending, and micro-drawing (micro-stretching), and also separates into fine blanking, progressive die, and forming die.
- Fine blanking: a stamping technique that accurately performs blanking to remove secondary process by forming a smooth cut.
- Progressive die/Compound die: all operations are unified on one single die, cheaper compared to single-operation die and improve yield consistency.
- Two types of forming die: one used for bending and the other drawing. Both may be combined with the progressive die.
The Differences between Microstamping and Typical Stamping
Micro stamping manufactures more precise and tinier parts than metal stamping. Requirements for precision and tolerance are also higher, within 0.1mm and the material workpiece is extremely thin. Layana’s production capabilities are listed below:
- part dimension: under 10mm
- feature size: ranges from a few micrometers to several hundred μm
- accuracy：±1〜10μm
Metal Stamping is a metal forming method that uses mechanical presses and stamping dies to convert flat metal sheets (blanking and other shaping processes) into specified dimensions, shapes and function. The manufacturability per part (dimension range, capable precision, and allowed features) will vary according to the complexity of the design.
What are the Processes of Microstamping?
The first step of micro stamping is the design and fabrication of the stamping die itself, and then different operations (e.g. blanking, bending, drawing, forming, etc.) are carried out accordingly to the precision requirement of the component.
- Blanking: The cutting process to shear the metal sheet in one press stroke.
- Bending: a manufacturing process that produces a V-shape, U-shape, Z-shape, etc.
- Drawing: also known as stretching, is a process that shapes a metal sheet into a three-dimensional shape
The Pros and Cons of Microstamping
The advantages of an automated micro stamping system offers mass production, complex operation, and pressure formation capabilities which reduces labor costs, metal scraps, and the need for secondary finishing process, respectively. The manufacturing process leaves the miniature part intact, removing the need for cleanup, and the flat unblemished surface is best for electroplating and coating to increase the durability of parts.
However, micro stamping doesn’t support low volumes of production due to die expenses and trial production costs, which greatly raises the price per piece and economically impractical.
The Advices for Microstamping's Maintenance
Micro stamping technology is an automated system for mass producing with high precision, but to maintain that productivity and precision yield, routine equipment (e.g. die, mold, press, etc.) maintenance is crucial. Even after the die is released from the press, regular inspection must be conducted on all equipment to maintain consistency, accuracy, and quality production.
Layana’s Microstamping Capabilities
Having assembled a professional R&D team with decades of micro stamping experience and expertise, Layana possesses the capability to manufacture various complex micro parts smaller than 10mm with ±0.03mm accuracy.
The Applications of Microstamping
Micro stamping technology is applied in semiconductors, electronic and information products (e.g. lead frame), biotechnology, medical machinery, aerospace, etc. Modern industries are all advancing towards utilizing more compact and precise parts.
- Aerospace
- Automotive
- Electronics
- Medical
- Optical
- Power Electronics
- Other fields
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The Materials of Microstamping
Aluminum, brass, bronze, cold-rolled steel, copper, stainless steel, titanium, and etc. are common metallic materials used in micro stamping. Picking the right material according to the requirement of the part is crucial to suit its functionality. e.g. Copper offers great ductility and malleability. Aluminum or stainless steel has good corrosion resistance.
| Material | Process |
|---|---|
| Aluminum | Micro Punching |
| Beryllium | Micro Forming |
| Brass | Micro Bending |
| Bronze | Micro Deep Drawing |
| Cold Rolled Steel | |
| Copper | |
| Stainless Steel | |
| Titanium |
Conclusion
As technology advances, portability and lighter weight has become the trend in designing consumer electronic goods. Portable goods such as smartphones, tablets, and memory drives require bulk supplies of micro parts urgently. Micro stamping may be achieved by utilizing Microelectromechanical Systems (MEMs), but the manufacturing cost of these intricately complex machineries cannot satisfy the growing demands of the current market. Therefore, micro stamping technology is becoming the main focus of development as size effect gradually exemplifies the difference between micro stamping and traditional stamping.
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