What is Sheet Metal Stamping?  

Sheet metal stamping is a high-speed manufacturing process that transforms flat metal sheets into complex shapes using custom-designed tools called dies. Unlike general fabrication (which involves cutting, bending, and welding), stamping focuses on mass-producing identical parts through rapid, repetitive press operations. A single press stroke can cut, bend, or stretch metal into components as simple as washers or as intricate as smartphone SIM trays.

Step-by-Step Stamping Workflow  

Design

An initial sketch or 2D/3D model with clear goals and complete details is an essential stage for a product to go from concept to finished product. Engineers can use computer-aided design (CAD) software or hand-drawn to comprehensively consider factors such as user needs, existing technology and equipment conditions, potential error avoidance, etc. during the design process, while clarifying key contents such as product functions, material selection, part geometry, mold design, tolerance and precision requirements, safety and environmental protection.

Stamping Forming

There are four steps in this stage, namely blanking, bending, drawing and forming. Blanking cuts the sheet into a designed shape, such as a hole, slot or outer contour, through a die. Bending uses ready-made or custom-made dies to bend the sheet into a specific angle or shape. Drawing uses a die to draw the flat material into a three-dimensional shape, such as a cup or box. Forming locally deforms the sheet, such as embossing, flanging, etc.

Post-Processing

After forming, the burrs generated during the stamping process of the finished product will be removed to ensure the smooth edges of the parts. Electroplating, spraying, anodizing and other treatments will be carried out as needed to improve the corrosion resistance and aesthetics of the parts. Parts that need to increase strength will be further heat treated, such as quenching or tempering.

Quality Inspection

To ensure the quality of parts, use measuring tools to verify that their dimensions and tolerances meet design requirements. Then, carefully inspect the surface for scratches, cracks, or other defects. Finally, conduct additional inspections or tests as needed to confirm the parts’ overall quality and functionality.

Assembly and Packaging

In sheet metal manufacturing projects, assembly is the final assembly process before the product is packaged and delivered. It can be the production and transportation of individual parts or a comprehensive production, assembly and transportation service.

Key Tools and How They Solve Problems  

•  Press Brakes:

Used for precision bending. Modern CNC brakes auto-calculate bend angles to compensate for springback .

• Progressive Dies:

A strip of metal moves through multiple stations in one die, combining cutting and forming.

• Lubrication Systems:

Oil or polymer sprays reduce friction during deep drawing, preventing splits in aluminum parts.

• Car Door Hinges:

Stamped from stainless steel using compound dies; 10,000+ parts/hour with <0.1mm variation.

• Laptop Chassis:

Thin aluminum sheets are drawn into seamless unibody frames, eliminating welding seams.

• Medical Device Springs:

Micro-stamping tools etch titanium sheets into biocompatible components for surgical tools.

Why Choose Stamping Over General Fabrication?  

• Speed: A 500-ton press produces 1,200 automotive brackets per hour.
• Consistency: CNC-controlled dies ensure every iPhone charging port fits perfectly.
•  Cost-Efficiency: No welding or assembly labor for integrated designs like dishwasher control panels.

Tips for Avoiding Common Defects  

•  Wrinkles in Deep Drawing → Increase blank holder pressure or apply Teflon-based lubricant.
• Cracked Corners → Use radiused punches instead of sharp edges.
• Dimensional Drift → Monitor die temperature; thermal expansion alters tolerances.

Conclusion  

Sheet metal stamping combines the precision of digital tooling with the raw power of hydraulic presses, making it the go-to method for high-volume metal parts. By understanding its tools (dies, presses), processes (blanking, drawing), and problem-solving techniques (controlling springback, lubrication), manufacturers can turn flat sheets into everything from electric vehicle battery trays to aerospace fasteners—all while keeping costs razor-thin.