Metal stamping is a versatile process that has been in use for centuries and continues to evolve today. While the basic operation of striking a piece of metal material with a tool remains largely unchanged, advances in materials, press technology, computerization, and automation have expanded the shapes, sizes, features, and tolerances stamping can achieve.
Here, we’ll look at some of the more recent innovations and developments that continue to change and improve metal stamping for many applications and industries.
Advanced Forming Techniques
Modern forming techniques and advances in press and tooling technology have made it possible to produce stampings that are complex, high-strength, and even miniaturized, all while holding tight tolerances. Some examples include:
- Hot Form Quench (HFQ). This technique is frequently used to create ultra-high strength aluminum stampings, especially deep drawn components. The aluminum or aluminum alloy is heated to its solutionizing temperature in an industrial furnace, then it is stamped in a press with cold tooling. The press only stays closed briefly, which causes rapid quenching that solidifies the metal’s microstructure, artificially age-hardening it. The piece can be further heat treated or further formed, depending on the application.
- Liquid Impact Forming (LIF). Liquid impact forming is a hybrid metalworking process that uses aspects of conventional stamping and hydroforming to form metal tubes. The tube to be formed is filled with water or another liquid, sealed on both ends to trap the liquid, and placed in the press. As the tooling presses on the tube, the liquid inside compresses and applies pressure to the walls of the tube. This pushes the material into the tooling and helps to form the final shape.
- Press Hardening. Also called hot stamping, this process is used to create complex stampings from ultra-high strength steels, which generally cannot be formed with standard, cold stamping. The material is heated in an industrial furnace, then placed in the press where it is quickly stamped with cold tooling.
- Micro Metal Stamping. This process is used to manufacture miniature parts and part features, some even at nano-scale, with intricate details for use in electronics, medical instruments or miniature devices, and more. These parts are often made from thin strips of metal coil with progressive stamping dies.
Smart Manufacturing and Automation
Many manufacturing processes have been computerized for decades; however, the advent of WiFi connectivity, robotics, and AI has created an Industrial Internet of Things (IIoT) that boosts accuracy and precision, shortens cycle times, and reduces waste. Examples of how these apply to metal stamping include:
- AI-Powered Quality Control. AI is quickly transforming quality control systems with machine learning and computer vision inspection to automate quality inspections and detect errors in real time. This reduces waste and time spent reworking components.
- IIoT-Enabled Presses. Connectivity between presses, motion controllers, conveyance, and material handling means movements can be synchronized for high-speed operations and precision placement. Computers can also use data analytics to monitor tool wear, press tonnage and speed, and make fine adjustments on the fly. In-die sensors can detect misaligned tooling, out-of-tolerance stampings, foreign objects, and other inefficiencies during production, instead of discovering errors once a batch is completed.
- Robotics and Automation. As with many areas of manufacturing, automation is transforming metal stamping by improving efficiency. Material handling robotic arms can feed raw materials into a press with perfect alignment over and over for minimal part variation, even at high operating speeds. Conveyors can be used to collect stampings and transfer them to the next workstation.
- Quick Die Change Systems. These automated systems enable rapid tool changeover to quickly swap tooling for one part to another, especially for the production of part families with similar features and minor variations. This reduces downtime and the manual labor involved in changing die sets and making fine adjustments.
- 3D Modeling. Based on CAD drawings, 3D modeling software creates a virtual model of a part and analyzes its dimensions, tolerances, and features for potential points of failure or manufacturability challenges. This is also an efficient way to visualize a part as a whole and predict how all of these aspects of design will behave in the real world. Additionally, it makes it easier to identify issues and make adjustments before spending time and money on tooling, materials, and even prototyping.
Material Innovations and Sustainability
As more businesses take steps to improve energy and material efficiency and reduce their environmental impact, waste reduction and sustainability have gained prominence in the metal stamping industry. Some innovations toward these ends include:
- Recyclable & Sustainable Metals. Steel and aluminum are almost infinitely recyclable, making them popular choices for sustainable manufacturing. Computerized tools that plan material use with minimal waste further reduce the amount of waste or scrap generated from stamping.
- Green Manufacturing Practices. Many innovations in stamping aim to save on energy costs and limit environmental damage. Examples include water-based lubricants, virtual modeling, rapid prototyping with recyclable plastics, and energy-efficient presses.
- High-Strength, Lightweight Alloys. Alloys with a high strength-to-weight ratio are more energy efficient in automotive and aerospace applications, without compromising structural integrity.
The Future of Metal Stamping
Innovations in stamping techniques, advanced and “smart” manufacturing technology, and improved materials will continue to shape the metal stamping industry. From shorter cycle times that bring products to market more quickly, to efficient use of materials, there’s never been a better time to partner with a forward-thinking stamper for your next project.
American Industrial has been at the forefront of metal stamping for over 40 years, prioritizing precision, efficiency, and excellent customer service. Contact us today to learn more about our stamping capabilities and what sets us apart from the competition.