Near Net Shape Stamping
Seeing the words "metal stamping" often causes one's thinking to gravitate toward the process of blanking out non-complicated, flat parts. We suggest that vision of metal stamping is very limiting. While it used to be common to send a component with any level of complexity directly to a machine shop rather than to a press, it doesn't have to be that way. Metal stamping is not limited to operations that only pierce or cut, rather a stamping die can be designed to also bend, draw, shape, and coin a range of metals and alloys. Complex geometries, cylindrical shapes with tight corner radii, and stringent tolerances can all be achieved through high precision metal stamping processes.
Winzeler Stamping Company has experienced great success with stamping to a near-net shape, essentially substituting stamping operations for machining operations. By designing a die that will allow for stamping a component as near as possible to its finished state in a single step, we maximize efficiencies, reduce cost, and enhance quality. This process relies upon engineering and designing a tool that will effectively replace almost all machining operations other than those necessary to achieve final tolerance specifications.
Generally, stamping processes have a lower variable cost than machining processes so any feature that can be stamped rather than machined is a potential cost savings for the customer. The traditional approach of machining a complex part can be very scrap-intense. In order to produce the part, the shape must be cut or ground from the raw material which often results in greater weight in offal than in the component itself. One of the primary advantages of near net shape stamping is that the stamping process utilizes material more efficiently than machining does. This often results in a significant cost savings in the per unit price of production. The cost to develop and build a die can be quickly recovered when running high volume parts and is especially worth consideration when working with more expensive metals like copper and stainless steel. Moreover, the process can also be considered a lean manufacturing practice in that it reduces waste in the form of material, energy, and labor.
Finally, near-net shape stamping supports the ability to manufacture a virtually perfect product without the variables that sometimes occur with machined product. Winzeler Stamping Company was pleased to have received an award from an OEM for whom we designed and managed a near-net shape stamping conversion a few years ago. Through collaboration and a comprehensive amount of R&D we helped implement the change. To date, we have experienced zero parts rejected out of millions of parts run and realized a 7 to 1 advantage in through-put versus a conventional machined part.
Winzeler Stamping Company offers the complete services of a talented engineering and tool design staff, an in-house tool room, as well as complete stamping and CNC machining departments.