The choice of material for stamping directly influences the cost price per component, the lifespan of the tooling, and the achievable tolerances. However, in practice, this choice is too often made based solely on the end application, without considering the production process. In this article, we will explain which materials are most suitable for stamping, how volume and tolerances influence the choice, and what the pitfalls are.

Why material and volume are inextricably linked

By stansen it all comes down to repetition. A press makes hundreds of strokes per minute. The material must be able to withstand that cyclic load time and time again without tearing, deforming, or slipping.

At low volumes, this load is limited. At high volumes, the interaction between material and mould becomes more intense. Harder alloys wear tools faster. Softer materials deform more easily at high speeds.

In practice, Eurotechniek regularly sees customers choose a material based on the end application, but forget to take manufacturability into account. A stainless steel part for a corrosive environment makes perfect sense, but if the annual production volume is 200,000 units, you are also asking for faster mould wear and higher tooling costs. Understanding that balance is the first step towards a good material choice.

The most common metals for sheet metal work and their properties

Cold-rolled steel is the most commonly used material for stamping. It is easy to machine, available in many thicknesses, and relatively inexpensive. For structural components, brackets, and switch plates, it is a logical choice.

Stainless steel offers corrosion resistance and higher strength, but requires more pressing force and wears tools faster. Aluminium is lightweight and easy to machine, but has lower mechanical strength. It is widely used in electronics and automotive for shielding plates and housings.

Copper and brass are excellent conductors and are used for electrical contacts and connector plates. They are good for stamping, but the material cost is higher. Each of these metals behaves differently during stamping, and that behaviour scales with your volume.

Tolerances: what is feasible per material?

Tolerances in stamping work are determined by three factors: die quality, material thickness, and the material properties themselves. Cold-rolled steel with a thickness of 1 mm will deliver tolerances of plus or minus 0.05 mm without problems with a well-calibrated die.

Stainless steel requires more precise adjustment of the cutting clearance to prevent fraying and tearing. For aluminium, the yield strength plays a role: the material deforms plastically more readily, which is advantageous for deep-drawn parts but can cause additional springback in flat die stamping.

Eurotechniek always sets the die clearance according to the specific material and the requested tolerance. This might sound obvious, but in practice, we see that generic die settings lead to dimensional deviations that only become apparent in large production runs. Discussing tolerance requirements early in the design process prevents costly adjustments later on.

Productivity versus material cost for large batches

At an annual volume of 10,000 units, the material choice differs from that at 500,000 units. At high volumes, every cent of material cost per component counts significantly. A pound cheaper material per kilo can save tens of thousands of euros over a year's production.

At the same time, you must take die life into account. A harder material such as stainless steel will wear out the die sooner. This means more frequent grinding or replacement of tooling, which also incurs costs. Therefore, the true total cost per part is obtained by adding together the material price, processing time per stroke, die maintenance, and rejection rate.

At Eurotechniek, we calculate these total costs for customers with larger production runs, ensuring that material choices are based on facts, not habits. A customer in appliance manufacturing switched from bare steel to pre-treated strip steel. The mould costs remained the same, but the post-treatment process was completely eliminated. This resulted in significant annual savings.

Material form and strip steel as a factor of production

Stanswerk preferably works with strip steel: a continuous material strip that automatically runs through the press. This makes the process fast and consistent. Not every material is available in strip form or economically viable to order as such.

Aluminium and copper are readily available in strip form. Special steels or less common alloys sometimes have to be cut from sheet, which involves extra processes and higher material costs. The width and thickness of the strip are also important factors. A strip that is precisely sized for your component minimises material waste.

When die-cutting, material efficiency is a significant cost factor. Nesting optimisation, where the die shape is placed as efficiently as possible on the strip, can improve material efficiency by ten to fifteen percent. For a part costing €0.50 in materials per piece at 300,000 units, that means a directly measurable result.

Surface treatment as part of material selection

A component rarely leaves the press in its final state. Stamping leaves cut edges and sometimes small burrs. Depending on the application, further treatment follows: countersinking, powder coating, anodising for aluminium, or passivating for stainless steel.

The surface treatment cannot be separated from the choice of material. Bare steel rusts quickly if not treated. Stainless steel is immediately corrosion-resistant, but more expensive to purchase and process. Pre-treated material, such as galvanised strip steel, saves a step in the process, but requires adapted tools because the coating affects the cutting clearance.

At Eurotechniek, we tailor materials and post-treatment to the final application and the desired process. This way, you avoid unnecessary steps and keep the lead time compact.

Frequently asked questions about choosing materials for dancewear

What material is most suitable for small series stamping?

For small series, cold-rolled steel is the most common choice. It is easy to process, available in many thicknesses, and relatively inexpensive. The die investment is limited due to low tool wear. For small series requiring corrosion resistance, aluminium is a good second choice due to its lower processing pressure.

How does material thickness affect achievable tolerances?

Thicker materials require greater press pressure variation per stroke, which makes repeatability slightly more difficult. With thin material, under 0.5 mm, tighter tolerances are achievable, but die adjustment requires more precision to avoid cracking. As a rule of thumb, tolerances of plus or minus one to two percent of the material thickness are achievable with well-maintained tooling.

Can I switch materials halfway through a series?

That is technically possible, but almost always requires modification of the die. The cutting clearance, the press pressure settings, and sometimes the strip guiding are material-specific. Defining a material choice before die production begins saves costs and prevents delays. Eurotechniek advises on material variants during the quotation phase, enabling you to make a well-informed decision.

Material selection is not a trivial matter

The material is not a detail you sort out at the last minute. It determines your cost price per item, the lifespan of your tools, and the quality of your final product over the entire series. Those who take material selection seriously early in the design process avoid costly adjustments later on.

Would you like to discuss the best material choice for your stamped parts? Contact Eurotechniek. We'll look at the drawing, volume, and tolerances with you, and provide you with concrete advice.