The 5-axis C-Series fabricates complex parts in large quantities and multiple sizes.

Denver-based Metalcraft, the only metalworking firm in Colorado with premium CNC machining, stamping, and sheet metal capabilities all under one roof, recently purchased C.R. Onsrud’s 5-axis C-Series to machine parts for its clientele, including a large company in the aerospace industry.

The 5-axis C-series’ Capabilities

The 5-axis C-Series performs intricate 5-axis millwork within its large capacity, yet compact framework. It’s an exceptionally versatile machine, adept at handling an array of challenging applications. In a machining world that’s generally populated with machines that can work within a space of 6 to 10 cubic feet, the 5-axis C-Series is capable of a work envelope nearer to 80 cubic feet. Specifically, it’s ideal for cutting specialized composite and non-ferrous materials that would otherwise be difficult or impossible to machine on other conventional processing formats. One of Metalcraft’s engineers, Chris Lindenberger, provided an overview of the machine and its production capabilities.

Metalcraft Industries produces parts made from honeycomb cores. These parts are made from materials like paper and cardboard in low strength and low load applications, such as snowboards, packaging, or furniture, to high strength and stiffness materials like composite glass and plastic materials to produce extremely lightweight components for aircraft and defense hardware. “Honeycomb cores are fabricated in an array of many hexagon-shaped cells, assembled into a continuous structure. It is a material comprised of nylon paper and phenolic constructed in a very complex fashion. If I showed you a piece of it, it would look very much like it was removed from a beehive.”

Basically, this new machine takes pieces of material, like aluminum or composite honeycomb, and it turns them into specialized pieces per their customer’s designs and specifications. Lindenberger noted the specific model Metalcraft purchased is the F98C—which can be operated manually or automatically. “If you need to turn a piece of composite material, like honeycomb, into the shape of a void inside a fighter jet wing, we now have a superior machine tool to do so. It’s capable of producing very complicated parts in large quantities or large sizes. That’s what it’s made for.”

Lindenberger further elaborated on the 5-axis C-Series and its manufacturing output capabilities.

“Imagine if you had 100, $80-million aircraft, consisting of more than a million parts each, all machined on tools like we’re talking about. They all begin as larger pieces of material, that while being processed become their desired shape as small bits of material are machined away. This machine is designed to use specialized tools to remove those small bits. It will eventually produce the finished component in the shape described by the customer’s engineering drawing. It’s like Leonardo da Vinci taking a large piece of stone and chiseling away everything that’s not the statue of David.”

Dimensions, Uses, And Industries

The 5-axis C-Series, which Lindenberger estimates is approximately 16 feet tall, 14 feet wide, and weighs six tons, is often informally referred to as the “honeycomb machine.” It gained this nickname because it can seamlessly transform composite honeycomb and foam-core material panels into highly specialized aeronautic and defense components. He comments further:

“We call the machine a honeycomb machine because that is really why we bought it. We have machined these same honeycomb components on conventional machines for some time and this new machine will give us improved and additional approaches to producing these components. If we take all the honeycomb work that we do now, which is very complicated, and move it to this format, this machine will impact our job of producing a flawlessly quality product with increased speed and repetitiveness.” 

The machine, also utilized in the automotive, furniture, packaging, logistics, medical device, and various other manufacturing industries, is extraordinarily precise and can simultaneously decrease downtime and increase uptime. Moreover, it diminishes the need for outsourcing, sharply enhances efficiency, and boosts productivity. For reference, thanks to the machine’s new, 5-axis large-format solution, Lindenberger predicts it could augment Metalcraft’s honeycomb machining capabilities by a large margin. But perhaps most important to the third-generation, family-owned manufacturing company that’s achieved a sterling reputation over three-quarters of a century, the 5-axis C-Series has multiple security features that make it remarkably safe to operate in the workplace. Lindenberger elaborates: 

“This machine has system failsafe features that prevent operators from entering an envelope that would expose their limbs or body to any of the moving parts of the machine. And thank goodness, all modern automated machine tools must have these capabilities; they can’t be sold without them. It is a very safe machine that has guardrails, entry barriers, and safety interlocks to prevent accidental operations with bodies at risk. Its computer will shut down operations when programmed safety protocols are breached.”

Readying For Use

Recently, factory technicians from the vendor have been installing the 5-axis C-Series at Metalcraft’s plant. Subsequently, programmers and operators received specialized training to learn about the machine and its functionalities. Now that it has been installed, Metalcraft employees are preparing setups, programs, and tooling so it can achieve peak performance on its first project. Although the 5-axis C-Series is expensive, Lindenberger is confident that its benefits will more than compensate for its costliness:

“This machine can do many things and do them quickly and accurately. It’ll help free up so many things in the business and we’ll be able to focus on other work and innovate in other ways. Once everybody pitches in and makes it work, it should be a great addition to our company.”

If you need to produce very complicated parts in large quantities or large sizes, give us a call. With this new machine, we can speed your production process.

Metal stamping and precision sheet metal fabrication are processes used to manufacture metal parts. While both processes have pros and cons, you must choose the most practical and efficient one for your project. Accordingly, let’s analyze metal stamping and precision sheet metal fabrication to determine which technique will best align with your design and production requirement needs.

What is metal stamping?

Metal stamping (or pressing) is comprised of multiple manufacturing processes that include, but are not limited to, blanking, bending, flanging, punching, and coining. This process can be completed in a single-stage operation or through several operations by placing a flat sheet of metal, in either coil or blank form, on a stamping press to shape it to its desired state.

 Metal stamping pros

• An ideal long-term, and cost-effective, option for mid-to-high volume production
• A precipitously higher throughput solution for producing large quantities and volumes of complex and precise parts than sheet metal fabrication
• Can be a highly automated process that helps reduce labor costs input and repeatedly produces tight tolerances
• High levels of reliability, repeatability, and reproducibility for high-volume parts and pieces
• Help reduce per-unit costs
• Reduced scrap rate
• Reduced labor costs

Metal stamping cons 

• High upfront tooling costs
• The time required to develop tooling often causes longer pre-production times
• Can be costly to implement design changes after tooling is produced 
• Short-run production has higher piece price costs due to longer setup times

What is precision sheet metal fabrication?

Precision sheet metal, which consists of a series of processes like punching, laser cutting, welding, bending, forming, hardware insertion, and assembly, is a valuable metalworking method that is employed to transform flat sheets of common steel, stainless steel aluminum, and many more alloys into virtually any shape. This robust process is used to produce a diverse range of parts and products and is especially useful when creating functional parts, such as panels, brackets, and enclosures.

Precision sheet metal fabrication pros

• Effective for creating complex products with mass customization 
• Shortened initial startup time 
• Easy to implement design changes and make adjustments 
• Greater flexibility and versatility 
• Extremely economical for short production runs
• Produces rapid, and far easier, prototyping

 Precision sheet metal fabrication cons 

• Higher labor costs and more labor-intensive
• Deep-drawn shapes not feasible 
• Requires a longer production period
• Slower production process
• Material waste can be higher because costs are generally more expensive

What process should you use?

Because we offer both metal stamping and precision sheet metal fabrication services under one roof, we can handle any project regardless of its requirements. Essentially, if you have a newer product that doesn’t have market adoption, we can fabricate parts without a large upfront investment. 

Conversely, if you have market adoption and require additional parts, our in-house tool and die production capabilities will allow us to quickly fabricate them at reduced per-unit costs. In this case, any upfront costs would eventually be offset and profits would be maximized. 

Moreover, for product development projects, combining our metal stamping and precision sheet metal fabrication services is a viable option. This process would allow us to make prototype parts and easily transition them for small-scale production. Hereafter, as the product lifecycle matures, we can increase large volume runs. 

Visit our facility so we can conduct a cost-benefit analysis to determine what process is more conducive to your needs.

Conclusion

Metal stamping and precision sheet metal fabrication are both common, and effective, metal formation methods. However, depending on a specific project’s circumstances, one process will prove to be more advantageous to create your product or part. With that noted, metal stamping is the more economical method as your product volume increases and order quantities grow. Ultimately, by reducing lead times and improving quality, metal stamping can help you minimize costs and maximize profits.

Do you have more questions? If so, get in contact today!

Hopefully, you now have a better understanding of metal stamping and precision sheet metal fabrication. Nevertheless, if any questions remain, please feel free to contact us. Metalcraft is the only metal manufacturer in Colorado that offers CNC machining services, precision sheet metal fabrication, metal stamping, contract manufacturing, and a vast array of post-production services all under one roof, forging raw material into a finished product is an art form and we’d love to discuss your project with you in greater depth. Give us a call today!

Metal fabrication and tooling experts are typically well-versed in the industry’s complicated terminology. Conversely, such business jargon can be confusing and, even worse, useless for individuals less familiar with metalworking. In case you fall into the latter category, we’ve decided to explain the processes, and detail the pros and cons associated with two of our offerings: progressive die stamping and single-stage die tooling. 

What Is Progressive Die Stamping?

Progressive die stamping is a cutting and cold-forming process that is frequently used to manufacture parts for a wide range of industries including, but not limited to, the fields of automotive, electronics, and appliances. Progressive die stamping, which is ideal for manufacturing large volumes of simple or complex parts, utilizes a die surface, high-tech sensors, piloting, and several individual workstations. The process starts when flat sheet metal (in coil form) is fed through a stamping press’ automatic feeding system. 

The flat sheet metal becomes uncoiled and a strip stock then transports it to each stamping station, where it can be coined, punched, stamped, notched, bent, drawn, blanked, and more to shape the part to its predetermined specifications. After being processed through the stamping die, the finished part is removed from the strip stock. Essentially, progressive metal stamping is attractive because it’s automated and the machine does the work by following an assembly line of steps before achieving its final form. 

Pros Of Progressive Die Stamping

Progressive die stamping can be a cost-effective way to help you quickly, and simultaneously, produce large quantities of complex parts. Specifically, the main advantages of progressive die stamping include:

• Reduced labor costs
• High-press tonnage
• Quick setup time
• Minimal scrap
• Requires only one press
• Allows unattended machining operation on the metalworking plant floor
• High repeatability and reproducibility 
• Rapidly, and consistently, produces multiple small parts with tight tolerances 
• Long production run lengths
• Decreased downtime
• Allows control of part location throughout the stamping process

Cons Of Progressive Die Stamping

• Generally pricier than line or transfer dies
• Usually requires precision alignment and setup procedures
• A coil feeder system is needed
• An open-ended press is needed so that the metal can be fed into the die
• If one station is damaged, the entire die set needs to be removed

What is Single-Stage Tooling?

Single stage tooling (also referred to as manual dies) is a simpler process that relies on one stage, rather than multiple stages, to shape flat sheet metal (in coil form) to its predetermined specifications. During this tooling process, which also employs punching, blanking, embossing, bending, forming, drawing, flanging, coining, and more, a part is either loaded by hand (manual dies) or loaded by machine tending robots (transfer dies) onto a die’s surface. 

Despite being a single-stage operation, this process can effectively handle short- and long-volume runs. Moreover, precision metal stamping creates and develops raised images and even three-dimensional parts that must have tight tolerances. Many intricate designs have zero room for error, with final measurements on target for .001” – .002” inches. To achieve this level of precision, it takes strict adherence to specifications established during the design process.

Pros Of Single-Stage Tooling

• A cost-effective method for manufacturing
• Easy to setup
• Requires fewer adjustments
• A high-quality, single-stage press has an extensive lifespan
• Offers a less complex, straightforward process for the production of parts
• Allows for a quicker return on investment (ROI)
• Requires minimum capital investment

Cons Of Single Stage Tooling

• It generally has a slower rate of production than progressive die stamping
• It can only handle one step at a time
• Dies need to be replaced when performing a new operation

The processes of progressive die stamping and single-stage tooling have created many products and parts that you handle on a daily basis. For example, soda can lids, tie clasps, and keychain clips were likely all formed from a giant roll of sheet metal steel. For all of us at Metalcraft Industries Inc., forging the raw material into a finished product is an art form. 

Hopefully, now that you have an understanding of progressive die stamping and single-stage tooling, you have a newfound appreciation for how metal stamping works and the terminologies behind the processes.

Need A Metal Part? Let’s Talk About Your Design.

We can help you produce any metal part you desire. We are the only metalworking firm in Colorado that offers CNC machining services, precision sheet metal fabrication, metal stamping, contract manufacturing, and a vast array of post-production services all under one roof. We offer tours of our factory floor by appointment. Give us a call and we will bring your metalwork to life.

A wide range of industries utilize precision metal stamping to create and produce quantities of products and parts—with a high degree of accuracy, speed, and precision. A custom-designed set of tool and die are installed into a stamping press, which then “stamps” the desired output from a coil of sheet metal. Precision metal stamping is ideal for projects that require a high volume of complex parts. Successful metal stamping relies on highly experienced toolmakers and innovative die processes, which makes it one of Metalcraft’s specialties.

Metal Stamping Processes

Custom jobs in the precision metal stamping process form shapes out of coils of flattened sheet metal. Depending on the tool and die required, output can be custom produced with bending, punching, tooling, coining, embossing, notching and flanging. 

The production run isn’t even the hard part—the design phase is the most important. Technicians and designers work closely with clients, using computer-aided design (CAD) software to create the desired part as accurately as possible. Depending on the requested volume of output, there are long-run progressive die stamping jobs and short-run die stamping jobs. Larger production runs realize greater economies of scale for clients.

Who Utilizes Precision Metal Stamping?

Cars

One of the most common examples of utilizing precision metal stamping is the automotive industry. Components like latches, fasteners, clips, and clamps are used throughout the body and frame of cars.

Construction

Many common power tools such as drills, saws, cutters, and jobsite tools utilize parts created by precision metal stamping. When you consider the amount of brands, sizes, powers and strengths of the millions of tools on the market, it’s easy to see why sheet metal fabrication is a high-demand service. Additionally, many of the brackets and plates used in the framing process are produced by precision metal stamping.

Interior Hardware

DIY home projects have become wildly popular. Ceiling fans, lighting fixtures, customized switches, door & lock assemblies, and cabinet pulls all include parts and pieces derived from precision metal stamping and fabrication. Additionally, there are multiple parts and pieces produced that go into all of our appliances, such as refrigerators, dishwashers and stoves.

Benefits of Precision Metal Stamping

For metal manufacturers, precision metal stamping is a standard process—but it includes many benefits for the client including lower die cost, secondary costs, and a high level of automation. Done right, jobs can be completed cheaper, with fewer technicians, and with more accuracy than other metal forming techniques.

If you’ve ever bought a pre-packaged wall-hanging kit or a set of L-shaped shelf mounts from a hardware chain like The Home Depot or Lowe’s, you’ve purchased a product that’s undergone precision metal stamping. Most people never think about how many of our most common product purchases were produced by precision metal stamping. 

Metal stamping is integral to the production of millions of items from home products to industrial items to heavy machinery. In this blog, we explain the processes behind this manufacturing staple.

What is metal stamping?

To give a definition in layman’s terms that anyone can understand, metal stamping is a cold-forming process that applies extreme force to create a permanently shaped piece of metal. Involved in the process are large tool and dies that are fed into a press that rapidly applies tons of force to cut and shape the metal into the specified objects.

Tool (and Dies) of the Trade

Precision metal stamping requires heavy machinery (“presses”) and a combination of custom tool and dies to fabricate jobs that meet a product’s precise specifications. Here’s an easy to understand description of each component:

Creating Metal Stamped Parts

The presses that exert the extreme force necessary to create these parts come in a diverse range of power. In fact, Metalcraft owns the largest press for hire machine in Colorado—capable of applying up to 400 tons of force, as well as tool and die sizes up to 54” x 108”

Tool and Dies

In metal stamping services, a tool is referred to as any mechanical device used to cut, shape, support, or mold metals. Jigs, fixtures, drills, and cutting blades all count as tools. Metalcraft has in-house toolmakers capable of adapting existing tools or building new ones.

Dies, by definition, only include tools that alter the shape of the metal in a functional way.

Metal Stamping Techniques

Depending on the size, scope, and output requiring precision metal stamping services, orders are completed using two kinds of techniques. These are:

Short-Run Die Stamping

Typically reserved for smaller, simpler metal stamping jobs, short-run stamping requires one custom tool for each operation. Examples include piercing, forming, drawing and trimming.

Long-Run Progressive Die Stamping

This technique relies on multiple die stations within one progressive die, each of which has its own function in a progressive process that culminates in the final, finished part. Using this technique creates process efficiencies that result in faster production speeds and cost-effective manufacturing.

Metalcraft – Denver’s Metal Stamping Experts

With over seven decades of precise fabrication experience, we believe that metal stamping is an art form. Our wheelhouse project in our stamping department is high-volume with repeatable product output. However, we’re also capable of running production for prototype and lower-volume products in our precision sheet metal departments. Our approach to every precision metal stamping order is to assess each and every job from a turnkey perspective. We address the production process from start to finish, with a goal of delivering the highest quality output at the most efficient price-point.

We hope you now have a better understanding of metal stamping and the tools and techniques applied to create custom fabricated products–many of which are part of our everyday lives. Like picture hanging kits. If your company requires a project that could benefit from precision metal stamping, contact us today to get started.