Stamping and die-cutting are two of the most efficient metal processing methods for high volumes. Process optimisation begins with tool development and continues through to material utilisation and cycle time management.

Stamping and punching utilise die-punch combinations that produce precise metal parts from sheet metal, aluminium, copper or other metal types in one or more strokes.

The greatest gains in lead time and cost per part are achieved through progressive tooling, material optimisation, and a stable pressing process.

Process optimisation in stamping is not limited to the press itself. Tool design, strip width, feed accuracy and press speed together determine the overall process performance.

The difference between stamping and die-cutting is that stamping uses a die and punch to cut out a shape from material, whereas die-cutting uses a die to cut out a shape.

Stamping is the cutting of metal: the shaping of a form from sheet material. Pressing is the deforming of metal: the plastic deformation of metal into a three-dimensional shape without removing material.

In practice, both operations are often combined in one tool or production line. A progressive die performs multiple processing steps sequentially as the metal strip is fed step-by-step through the tool. Each stroke of the press produces a (partially) processed part. At the end of the strip, a fully finished product emerges.

The distinction is technically relevant as it influences the choice of tooling, the pressing force, and the material properties:

• Stamping (cutting)Cutting, punching, blanking. Material is separated via shear stress
• Stamping (distorting)Deep drawing, bending, pressing. Material is plastically deformed via compressive and tensile stress.
• Combination processesfine blanking, progressive die stamping, transfer press. These combine separating and forming steps in a single tool or press line

Een progressief gereedschap is een die vervaardigd op een pers, die verschillende productiestappen in één enkele die-operation uitvoert naarmate het materiaal door het gereedschap wordt getrokken. Elk station in het gereedschap voert een specifieke bewerking uit, zoals vormen, ponsen of snijden, en elke keer dat de pers naar beneden komt, wordt het materiaal naar het volgende station getransporteerd en wordt de volgende bewerking uitgevoerd. Dit maakt een snelle en efficiënte productie van complexe delen mogelijk.

A progressive die, also known as a follow-on die or progressive tool, divides the manufacturing process across multiple sequential stations within a single die, so that each press stroke produces a complete part.

This makes progressive stamping structurally more efficient than single operations where the part is manually reset after each step. The metal strip is automatically fed step by step via a roller feeder or gripper feeder. The positional accuracy of this feed directly determines the dimensional accuracy of the finished product.

Advantages of progressive tooling over single dies:

• Higher output per houreach press stroke delivers a finished part, without any manual intervention between machining steps
• Lower labour costsThe process is fully automated, including the feeding and removal of plate and product.
• Higher repeatabilitythe position of the strip in the tool is mechanically secured via feather quills, which minimises measurement deviations between strokes
• Fewer tool changesmultiple operations in a single die reduce setup time during production changes
• Compact material flowone continuous strip process is logistically easier to control than several separate production steps

The complexity of tool design increases with the number of stations, but the production cost per part decreases significantly at volumes from approximately 50,000 pieces per year.

Six parameters that determine process performance

Process performance in stamping and punching is determined by six technical parameters, each with a direct influence on cycle time, dimensional accuracy, tool wear, and material utilisation.

• ClearanceThe clearance between the punch and die, expressed as a percentage of the sheet thickness. Too little clearance increases the cutting force and accelerates wear. Too much clearance causes burrs and dimensional deviations. The optimal clearance is material and thickness dependent. For cold-rolled steel, this is typically between 5 and 12 percent of the sheet thickness.
• Strip width and material utilisationThe width of the supplied metal strip determines how much material is used per component. An optimised nesting layout increases material utilisation and directly lowers the raw material cost per component.
• Beat speed (beats per minute)A higher press speed increases output but places higher demands on feed accuracy, tool cooling, and lubrication. For progressive dies with thin sheet thicknesses, speeds of 200 to 600 strokes per minute are common.
• Nutritional accuracyThe step with which the strip is fed per stroke determines the position repeat. Deviations of more than ±0.05 mm will lead to dimensional inaccuracies in the final product with complex geometries.
• Lubricant and lubrication methodLubrication extends tool life, reduces cutting force, and improves the surface finish of cutting edges. The choice of lubricant depends on the base material, machining temperature, and any post-processing requirements.
• Tooling material and surface treatmentTool steel quality HSS (High Speed Steel) or PM steel (Powder Metallurgy Steel), combined with a PVD coating (Physical Vapour Deposition), significantly extends tool life with abrasive materials or high production speeds.

Material utilisation and strip optimisation

Material utilisation, the percentage of the input strip that actually ends up in the final product, is one of the most direct cost-determining factors in stansen at high volumes.

With a poor nesting layout, material loss can amount to up to 40 percent of the input strip. With an optimised layout, this loss decreases to 15 to 25 percent, depending on the product geometry. The difference in raw material costs for materials such as stainless steel, copper, or brass is immediately significant.

Strip optimisation methods

• Rotating nestsThe parts are screwed onto the strip so that the contours fit more closely together.
• Single versus multiple nestingmultiple components side-by-side on one strip, depending on the strip width and press opening
• Reststrip reuseWaste material at the end of the coil is used for smaller components or returned as scrap with a known composition.
• Computational nesting softwareFor complex geometries, software calculates the optimal product placement on the strip, including minimum bridge distances between products.

At Euro-Techniek, material utilisation is calculated before tool production, as part of the technical proposal for each new press product.

Fijnstansen is een metaalbewerkingsproces dat wordt gebruikt om onderdelen met een zeer precieze en gladde snede te produceren. Het is een proces waarbij een stansmes en een matrijs worden gebruikt om materiaal door een opening te snijden, wat resulteert in een schone en nauwkeurige snede. Fijnstansen is geschikt in de volgende situaties: * **Hoge precisie vereist:** Wanneer de nauwkeurigheid van de snede cruciaal is, bijvoorbeeld bij onderdelen voor de auto-industrie, de luchtvaart of medische instrumenten. * **Gladde snedeoppervlakken:** Als er een glad, braamvrij snijoppervlak nodig is zonder verdere nabewerking, wat de productiekosten kan verlagen. * **Minimale vervorming:** Om te voorkomen dat het materiaal rond de snede vervormt, wat bij conventionele stansprocessen wel kan gebeuren. * **Productie van complexe vormen:** Fijnstansen kan worden gebruikt om complexe vormen en profielen te produceren die moeilijk met andere methoden te realiseren zijn. * **Massaproductie:** Het proces is efficiënt en productief, waardoor het ideaal is voor de productie van grote aantallen identieke onderdelen. * **Dunnere materialen:** Fijnstansen is vaak effectiever bij het bewerken van dunne tot middelmatige diktes metaal. Kortom, fijnstansen is de aangewezen methode wanneer een hoge kwaliteit, precisie en een schone afwerking van het gestanste onderdeel essentieel zijn.

Fineblanking is a special stamping process during which the sheet metal is clamped over its entire surface during the cutting process, resulting in a smooth and perpendicular cut edge across the full sheet thickness, without the tearing that occurs with conventional stamping.

In conventional die cutting, the cutting edge consists of a shiny shear section (approximately 30 to 50 percent of the sheet thickness) and a rough tear-off portion. In fine blanking, the entire cutting edge is smooth, making post-processing unnecessary and enabling tighter dimensional tolerances.

Fine-tuning is the right choice when:

• Flat, smooth cutting surfaces are functionally required without post-processing, for example in the case of guide or bearing surfaces
• Close tolerances are necessary. Fineblanking achieves tolerances of ±0.01 to ±0.05 mm, depending on sheet thickness and material.
• Sheet thickness between 1 and 16 mm applies. Alternative processes are generally more efficient outside this range
• The volume is high enough to justify the higher tooling and press investment. Fine blanking requires a triple-action press with specific clamping force.

Applications where fine blanking is used structurally include brake components, gear plates, switchgear components, and safety components in the Automotive in mechanical engineering.

Process optimisation as part of product development

Process optimisation in stamping doesn't start on the shop floor. It begins in the product design phase, where geometry choices directly determine which process is feasible, how the tooling is constructed, and what the cost per part will be.

A design that does not consider minimal bridge instructions, pitch limitations, or minimal gap distances leads to tooling that wears out faster, runs slower, or produces more scrap. Design for Manufacturing (DFM) is therefore not an optional step, but a technical prerequisite for an efficient stamping process.

At Euro-Techniek, each new mould product is technically assessed for manufacturability, tooling complexity, and expected cycle time before a final tool design is approved. Contact us for a technical assessment of your stamping component or production situation.

Frequently asked questions