Precision Manufacturing for Intricate Stamping Parts

Intricate stamping is a process used to manufacture irregularly shaped and complexly structured metal parts. It mainly uses multi-station progressive dies or composite dies to make the material present different geometrical shapes through forming methods such as punching, drawing, bending, etc. in order to meet the manufacturing needs of complex parts.

Main Characteristics of Intricate Stamping

Complex and Asymmetrical Part Shapes: Such as irregular contours, polygons, and parts with features in multiple directions.

Special Die Structures: Customized dies are required, which may include mechanisms such as wedges, sliders, and floating punches.

Diverse Process Combinations: Usually completed through multi-step or progressive dies, including operations like punching, bending, forming, and trimming.

High Requirements for Die Design: Design must consider material flow, springback, and strength distribution to avoid forming defects.

Common Intricate Stamping Process Combinations

Irregular blanking + Forming + Trimming

Multi-angle bending + Flanging + Embossing

Irregular hole punching + Side punching + Deep drawing

In-die tapping + Pre-punching for clinching + Flattening

Common Intricate Stamping Process Combinations

Irregular Stamped Parts are characterized by complex structures and a high degree of customization. In their design and production processes, they not only require precision stamping manufacturing but also often involve the integration of various supplementary processes:

Riveting

This includes Self-Piercing Riveting and Press-fit Nuts, used to fasten stamped parts to other metal or plastic components.

Welding

This includes Spot Welding and Laser Welding, suitable for connecting parts that require high structural strength and sealing capabilities.

In-die Tapping

This technology directly forms threaded holes during the stamping process, eliminating the need for subsequent machining steps. It significantly improves production efficiency and consistency, particularly for medium to large-volume production.

Cold Heading

A type of plastic forming process often used in conjunction with stamping, especially for producing fasteners with complex head structures (e.g., cross-slot, hexagonal heads).

Typical Structural Types of Intricate Stamped Parts

Curved Surface Parts: Automotive lamp covers or bathroom hardware housings, these parts often require processes such as deep drawing and forming to create complex curves.

Micro Precision Structures: Connector terminals and precision electrode sheets, typically involving micro-holes, micro-bends, and laminated structures. These require extremely high die precision and stamping gap control.

Multi-directional Composite Features: Brackets with composite structures like side holes, flanging, and bending. These parts need to be processed through sliding mechanisms or progressive dies, completing multiple steps.

Irregular Holes/Slots: Non-circular gear holes, cooling slots, and special connection ports.