Metal Forming of Brackets in Bulk Requires Progressive Power Presses

Metal brackets are the unsung heroes of countless structures and devices we rely on daily. Whether holding together pieces of furniture, supporting electrical enclosures, or stabilizing building frameworks, these seemingly simple components play a crucial role in our everyday lives. The importance of efficient and precise manufacturing processes for metal brackets cannot be overstated, particularly when it comes to high-volume production.

Diverse Uses of Metal Brackets

Metal brackets serve a multitude of functions across various industries. Here are ten examples showcasing their versatility:

1. Furniture Assembly: Brackets are used to connect and support furniture components, such as shelving units and cabinet fittings.

2. Electromechanical Equipment: Brackets hold and position electronic components within devices like computers and appliances.

3. Building Materials: They are integral to constructing frameworks for walls, ceilings, and other structural elements.

4. Automotive Parts: Brackets secure components within vehicles, such as engine mounts and suspension systems.

5. HVAC Systems: They support and stabilize heating, ventilation, and air conditioning equipment.

6. Signage: Brackets are used to mount and display signs in various commercial and public spaces.

7. Plumbing: They hold pipes and fittings in place, ensuring a secure and stable installation.

8. Electrical Installations: Brackets support electrical panels, conduit, and other wiring infrastructure.

9. Shelving Units: They are critical for creating stable and functional shelving systems in both commercial and residential settings.

10. Structural Reinforcement: Brackets add strength and stability to structural elements, such as beams and columns.

The Importance of Good Bracket Design

Designing metal brackets involves more than just creating a functional piece; it requires a deep understanding of the forces and stresses the bracket will encounter. Engineers and product designers are responsible for ensuring that brackets meet specific strength, durability, and aesthetic requirements. Good bracket design considers factors such as material selection, load-bearing capacity, and compatibility with other components.

The Role of Metal Stamping Power Presses

Metal stamping power presses are essential in transforming flat sheets of metal into fully formed metal brackets. These presses use high pressure to shape metal into desired forms through various stamping operations. The process allows for the creation of brackets with precise dimensions and often complex geometries, catering to different applications and specifications.

Manual Fed vs. Progressive Sheet Metal Stamping Presses

There are significant differences between manual-fed metal stamping presses and progressive sheet metal stamping presses.

• Manual Fed Metal Stamping Press: This type of metal forming press requires the operator to manually feed individual cut sheets of metal into the press for each stamping operation. While suitable for small production runs or prototyping, this method is less efficient and scalable for large volumes due to its slower pace and higher labor costs.

• Progressive Sheet Metal Stamping Press: In contrast, a progressive stamping press automates the entire process. A length of sheet metal is fed continuously through a series of die stations, with each die station performing a different stamping operation as the strip of sheet metal progresses through the press. This method allows for high-speed, high-volume production and ensures consistency and precision across all steps.

The Manufacturing of Metal Stamping Dies

Metal stamping dies are critical tools in the stamping process. A die is essentially a custom-made mold that shapes the metal into the desired bracket form. The die-making process involves designing and machining the die to achieve the precise shape and dimensions needed. Die makers for metal stamping presses use various machined metal parts to create dies that can handle multiple forming operations, including punching, bending, and embossing.

Why Progressive Stamping Is Ideal for Bracket Production

Stamping metal brackets often requires multiple forming operations, including cutting, bending, and embossing. Using a single die to complete all these operations in one go can be highly efficient and cost-effective. Companies that perform progressive metal stamping in PA are particularly well-suited for stamping tasks because it streamlines the production process by combining several operations into one continuous sequence and their proximity to major thoroughfares, rail lines and port facilities. Progressive stamping processes speeds up production but also reduces material waste and ensures high precision across all parts.

The Benefits of High-Volume Production

For manufacturers, producing metal brackets in higher volumes can significantly lower the per-part costs. By leveraging the capabilities of metal stamping shops and partnering with experienced metal fabrication companies near me, businesses can achieve greater efficiency, consistency, and cost-effectiveness in their bracket production. Investing in a metal stamping shop with advanced equipment and skilled die makers for metal stamping presses ensures that you get the best results for your high-volume needs.

In summary, whether you’re looking for progressive metal stamping in PA or seeking a reliable metal stamping shop, focusing on bulk production can help you reduce costs and improve your product’s overall quality.

Metal Brackets Are Used Everywhere But Are Not Easy to Make

The production of metal brackets through sheet metal stamping is a critical process in manufacturing, involving meticulous design and powerful machinery. The journey begins with the mechanical design process, often carried out by mechanical engineers or industrial designers. These professionals use computer-aided design (CAD) software to create detailed blueprints of the bracket, specifying dimensions, material type, and any special features such as holes, bends, or slots. The design must ensure that the bracket can withstand the mechanical stresses it will encounter in its final application while being cost-effective to produce.

Metal brackets are ubiquitous in various industries due to their versatility and strength. Here are five industries that extensively use metal brackets in their equipment:

1. Automotive Industry: Metal brackets in automobiles secure various components such as engines, transmissions, exhaust systems, and interior fittings. These brackets must be robust to handle the vibrations and stresses of vehicle operation.

2. Construction Industry: Metal brackets are essential in building frameworks, supporting structures like beams, and securing pipes and electrical conduits. They ensure structural integrity and safety in both residential and commercial buildings.

3. Electronics Industry: In electronics, metal brackets hold circuit boards, components, and assemblies in place within devices like computers, televisions, and mobile phones. They need to be precisely manufactured to fit intricate designs.

4. Aerospace Industry: The aerospace sector uses metal brackets to secure and align critical components within aircraft. These brackets must be lightweight yet strong enough to endure extreme conditions during flight.

5. Medical Equipment Industry: Metal brackets in medical devices and equipment secure parts, supports, and assemblies, ensuring reliability and safety in demanding medical environments.

The production process begins with sheet metal stamping, a method favored for its efficiency and precision. Metal stamping presses mold and form metal brackets by applying high pressure to a sheet metal blank between a die set. This process is preferred due to its ability to produce complex shapes with tight tolerances at high volumes, reducing the need for additional machining or finishing.

A metal stamping power press differs significantly from a typical press brake. A press brake is used for bending and folding operations, manually or with CNC control, to form parts from sheet metal. In contrast, a metal stamping power press can perform a variety of operations such as punching, blanking, embossing, bending, and flanging, all in a single stroke or series of strokes. This versatility makes it ideal for producing intricate and high-volume parts like metal brackets.

Within metal stamping, there are two primary types of presses: manual sheet-fed stamping presses and progressive sheet-fed stamping presses. A manual sheet-fed stamping press requires an operator to manually feed the sheet metal into the press for each cycle. This method is suitable for low-volume production or simple parts but is labor-intensive and less consistent.

On the other hand, a progressive sheet-fed stamping press uses a continuous roll of sheet metal that feeds through the press automatically. The strip of sheet metal passes through multiple stations, each performing a different operation, resulting in a completed part by the end of the line. This method, known as progressive metal stamping, is highly efficient for high-volume production and complex parts, as it reduces labor costs and ensures consistent quality.

Most metal stamping companies in PA and beyond often leverage these advanced techniques to offer their custom sheet metal fabrication services. They can take over sheet metal stamping projects from design to production, ensuring seamless execution and high-quality results. Companies like FBF Inc specialize in this area, providing reliable and efficient production of metal brackets and other stamped parts.

In conclusion, the sheet metal stamping process is vital for manufacturing durable and precise metal brackets used across various industries. Whether it’s the automotive, construction, electronics, aerospace, or medical equipment industry, the need for high-quality brackets remains constant. FBF Inc stands out in this competitive field, known for their fast turnarounds and competitive pricing, making them a go-to choice for businesses needing custom sheet metal fabrication. If you’re looking for expert metal stamping services, consider FBF Inc for your next project.

Automotive Assembly Requires That Metal Parts Arrive on Time

Auto assembly operations rely on hundreds of 3rd party vendors to manufacture and ship thousands of different parts often to one location. Material management and supply chain management are integral parts of a successful assembly line operation. Just in Time inventory systems were introduced many years ago and transformed how automobiles were made. This article will help you understand the supply c26hain from the metal stampers perspective.

In the 1960s, the Japanese took a first step toward a perfect manufacturing world by introducing Just-In-Time (JIT) manufacturing. The intent of JIT is to enlist the cooperation of all links in the supply chain to make manufacturing more efficient and cost-effective. Nowhere is this concept more visible today than in the US automobile industry.

The JIT Methodology Requires More Than Just a Leap of Faith

US automotive assembly plants operate on the premise that components will arrive on time. Arriving late could cause an interruption or even a stoppage of the assembly line. Arriving early requires the company to store, track and pay for components that they don’t yet need. Making JIT manufacturing work successfully requires commitments to be made and kept by all suppliers in all supply chains. Even one supplier missing a scheduled delivery could cause an avalanche of delays or even shutdowns.

On-Time Delivery of Stamped Metal Components Keeps the Assembly Line Moving

Today, automobiles are designed to include complex stamped components which requires progressive metal stamping. This is a multistep operation where a blank coil of metal is stamped using a series of die stations that punch, bend, form, and eventually cut this blank into fully formed metal parts. This can be done by moving the item through a multiple stamping stations or by specialized equipment that can complete the multiple stamping operations with a single setup. Regardless of how the multiple steps are performed, the real hero here is the stamping die maker who interprets the part specifications, manufactures the necessary dies and recommends setup procedures.

Stamped Metal Components Must Be Cost-Effective

The challenge facing metal stampers is to deliver stamped components at a fair price and on the agreed schedule. The obstacles to overcome are equipment setup charges and long lead times. On a per piece basis, equipment setup charges can be reduced with high quantities of long run stamping. This may require the supplier to inventory a quantity of completed stampings until it is time to ship them. Most progressive metal stamping companies that serve the automobile industry are larger organizations with some serious metal stamping equipment and inventory capacity. Although the best partners can work together to minimize the need to inventory parts and deliver parts just in time for the assembly process to ramp up.

Metal Stamping for Kitchen, Laundry and HVAC Equipment

The process of transforming flat metal sheets into various shapes by placing them on a tool and die surface in a stamping press is called metal stamping or pressing. Custom metal stamping is employed when making a variety of appliances in kitchens, laundry and the HVAC equipment for homes.

What Are the Various Types of Metal Stamping Presses?

Stamping presses can be hydraulic or mechanical. The types of metal forming can include punching, embossing, cutting, blanking, coining, flanging and bending through a machine press, performed through multi-step or single-step operations. Typically, cold metal sheets of carbon steel are used for stamping. Some additional metal types can range from stainless steel, aluminum, brass, and a substrate called Inconel.

What Components Are Created by Stamped Metal?

Metal stamping companies in Philadelphia are producing a number of products and components that are used throughout the appliance manufacturing industry. A few of the metal components used in manufacturing of appliances are clamps, springs, washers, metal plates, bracketry, ground straps, and fan systems. Long run stamping often takes place on a progressive die press and is used to complete multiple metal forming tasks in a single pass through the press. Here are some products made with the help of progressive metal stamping:

• Brackets and brushing for door and instrument panels

• Heat sinks and shields with various specifications and imprints

• Wire forms, such as terminals, rings, links, fasteners, hooks and springs

• Assemblies

• Lead frames for microchip management and electronics

What Are Some Sheet Metal Stamping Applications in the Appliance Industry?

Here are a few of the products made with sheet metal stamping in commercial and domestic appliances:

• Washers and dryers

• Stoves and ovens

• Outdoor kitchens

• Refrigeration systems

• Dishwashers and waste disposal units in sinks

• Pool and spa pumps

• Garage door and security systems

• HVAC units and water heaters

• Thermostats and temperature control units

• Irrigation and filtration systems

What Types of Metal Stamping Are Currently Available?

Depending on product design, its uniqueness, specifications, development stage and needs, and the production time frame, most metal stamping companies in Pennsylvania offer two types of metal stamping:

• Long run stamping, also known as progressive stamping and deep drawn long run stamping, is most commonly used and can produce bulk orders at high rates of 800 or more units per minute. It is a fast and cost-efficient method for large volumes, provided the number of units can even out tooling costs.

• Short run stamping is ideal for the vetting or testing phase of design and development as it does not require a lot of monetary investment. It offers fast turnaround periods and low tooling costs.

Punch Press or Laser? Choices for Cutting Metal

Metal workers are tasked with manufacturing high quality, marketable products for their clients. Metal fabrication often starts with sheet metal materials that need to be cut and formed into usable metal parts that get moved along the supply chain to a point of final assembly. In metal working, there are different options for cutting, forming, coining, piercing, punching and bending the metal into the finished product your company needs. Several methods involve what is called a punch press, and another one entails the use of a high-powered industrial laser. Each uses a different process, achieves different end results and holds distinct advantages.

The Punch Press

Punch presses operate by first developing cutting dies, forming dies or progressive die sets. The die is the tool within the press used to cut and or form the metal, and a progressive die set is used in machines where coils of sheet metal material pass through several stations within a die set in one pass. Punching is a form of metal stamping, which is when a die is used to cut metal blanks with the aid of a die and a power press. The punch press is about speed and high-scale production, and is characterized by a number of features:

• Force or power used to cut the metal

• The tooling die and complexity of the die

• Size of working area on the metal blank

• Frame type

Progressive long run stamping, another fast and cost-effective method, uses a power punch press. The material (in coil form rather than pre-cut sheets) involves multiple cutting and forming stages through a single machine before the desired result is achieved. Precision metal stamping is a bit different; this process converts flat sheet metal into different commissioned shapes maintaining very tight tolerances.

Laser Cutting

A slightly more modern technique, industrial laser cutting services is about precision. A beam of heat energy sears into the metal and melts the excess away. This energy is often operated by CNC (computer numerical control). There are some particular projects for which laser cutting is best to use:

• Tight intricate cuts

• Multiple metal blanks all cut from the same plate of metal

• Short run projects where tooling costs need to be avoided

There are many benefits to sheet metal laser cutting. For instance, laser cutting pre-painted metal without scarring the paint is possible with certain fiber lasers. There is also less chance of contaminating the material than with the cutting edge used in mechanical cutting.

Strengths and Weaknesses

Overall, both punch press cutting and laser cutting have certain advantages and disadvantages in the industry. Each are an asset to the task of metalworkers and their field, but in different ways. For more information, seek out a professional quote today.

Progressive Die Stamping Has Not Changed Much in 20 Years

You can see the impact of metal stamping using progressive dies in the building trades, consumer products, automobiles and the equipment we use to manufacture “things”. From everyday appliances in our homes to heavy machinery for large-scale industry, die stamped parts are in most every metal part in use today. While innovations continue to lead the metal forming industry forward, the foundation of progressive metal stamping remains the same, set in place in the early and mid-20th century. In the decades since, little has change because progressive die stamping methods of metal forming are basic; even cutting-edge manufacturers still follow the guidelines set in the 50s, and they still serve well today.

Early History of Progressive Die Stamping

The 1896 treatise titled The Press Working of Metals by Oberlin Smith, together with J.L. Lewis’s Dies and Die Making a year later, discussed “follow-on” tooling and the use of “successive gang cutting” techniques.These were the early beginnings of progressive dies. At its onset in the early 20th century, progressive dies saw fairly limited usage among companies in need of in-house manufacturing. Contract tool and die makers still relied on single-operation presses and workers loading and unloading materials by hand to transfer them between dies - a slow and often dangerous task, as hand-feeding strips and parts meant exposing unprotected hands to moving parts. The post-WWII metal manufacturing industry pushed production demands too increase outputs, and worker injuries on these single function hand transfer presses were becoming increasingly commonplace.

The Start of Modern Metal-Stamping Tradition

In 1953, design engineer Ed Stouten started a die design business called the Capitol Engineering Company in Grand Rapids, MI. He proposed an alternative: a multi-station progressive die where parts remained on the strip between operations and scrap material was reused. Sheet metal bending, cutting, punching and forming became a continuous process with little manual input between stages. Impressed, tool and die makers spread the word, and everyone wanted to try this new progressive die stamping process. Stouten developed an official manual and training course, Progressive Dies for Designers, Engineers and Manufacturers, and spent the next 50 years traveling the world along with leading die designer Arnold Miedema, giving seminars to share these new ideas.

The Legacy of Progressive Die Stamping

The fundamentals of progressive metal stamping remain the same not because of stagnation, but because of how significant the development was, and is, to the sheet metal bending industry. Stouten and Miedema’s seminars and designs remain vital for most tool and die makers in Pennsylvania and those outside our region. Manufacturers and customers everywhere owe it to Stouten’s work for the production of high-quality, reliable and safe die-stamped metal parts.

Challenges and Considerations of AHSS Metal Stamping

Designing and producing lighter-weight vehicles is a primary goal of some automobile manufacturers. Less weight allows for improved performance, safety and fuel economy while also reducing material costs. Advanced high-strength steel (AHSS) alloys represent a strong candidate for use in structural components of automobiles. They also present new difficulties in alloy composition; OEMs should pay attention to ongoing research in their formation, properties and effective stamping of these metal parts.

Observed Advantages of AHSS

Conventional mild steels have low carbon content and minimal blending elements which result in simple microstructures. AHSS alloys use carefully controlled additions of alloying elements to produce complex multi-phase structures with unique mechanical properties. There are a variety of AHS steel compositions and their properties provides considerable versatility. Dual-phase (DP) steels and transformation-induced plasticity (TRIP) for example, already see considerable use in vehicles. DP steels are highly resistant to fractures and necking. TRIP steels demonstrate a capacity for high energy absorption under sudden strain, excellent for the “crumple zones” of vehicles.

Formability Concerns of AHSS

Formability - the ability of a piece of metal to undergo plastic deformation without sustaining damage - is a critical trait for automotive alloys to ensure that parts do not fracture within metal forming presses. AHSS alloys, however, exhibit issues with formability as it relates to springback during some more complex precision metal stamping processes. Assessing the related mechanical properties of AHSS, in turn, is difficult with usual testing because the multi-phase structure leads to non-constant strain hardening. The viscous pressure bulge (VPB) test has shown promise, though, in constructing flow stress curves for AHSS samples.

Effective Modeling of Fracture States

The forming limit curve (FLC) is a standard in predicting the forming behavior of sheet metal to illustrate stress states that result in fracture. Traditionally, this involves a series of tests at varying ratios of shear and strain to determine when fracture occurs, but the variability of AHSS responses to strain make this especially costly in time and materials. The Center for Precision Forming at Ohio State University, however, has demonstrated a “three-point technique” for approximating the FLC with just three tests: pure shear, pure strain and biaxial tension. This can provide a more time- and cost-effective method for OEMs and their progressive metal stamping companies they work with.

The advances made in newer metal forming presses allow sheet metal stampers in PA to make fine adjustments to speed and force when forming critical shapes. There is great promise for precision metal stamping in the automobile industry. Further research in controlling the properties and performing effective testing and working will help manufacturers realize goals of more efficient automotive design.

Press Maintenance and Safety is Important

Stamping metal components uses very large equipment that has often been around for a few years. To fill orders and reach new customers, managers must work to reinforce a safe metal stamping environment. Everyone who works on or around the press at the metal stamping company must be committed to press maintenance and safety.

Training the Individual

Before anyone can work on a large power press, he or she must receive and understand stamping equipment training. The type of training delivered should include information about wearing personal protective equipment like goggles, steel tipped shoes and learn how to operate the press safely. It should also outline procedures for identifying hazards and reporting risks. Progressive metal stamping requires everyone to commit to both initial training and retraining. With a comprehensive training program, supervisors are confident employees know the safety rules.

Having a Zero-Tolerance Policy

Metal stamping power presses are incredibly powerful machines. They are also very dangerous if someone operates them in a way they were not intended to be used. Metal stamping company supervisors realize they must have a zero-tolerance policy for press misuse or unsafe behavior. Workers also must conduct press maintenance evaluations truthfully, pledging never to overload presses or misuse equipment.

Using Die Blocks and Cable Covers

When trying to stay on track to complete an order, workers may be tempted to use die blocks for other purposes outside of their intended purpose. Simply put, the original die blocks for a project are company assets just as the equipment itself. Die blocks should not be used to stand on, raise bins off the floor or turned in a press to hold it open. When not in use, they should be returned to the tool and die inventory room. Likewise, no safety cable should be exposed. Instead, supervisors must be certain all necessary covers and other protective pieces are securely in place.

Identifying Hazards

To avoid accidents, the press must be free from all hazards, scrap, foreign debris or anything not part of the safe operation of a power press. Everybody on the floor must be responsible for identifying all risks without exception. Tripping hazards, sharp objects, and other dangerous items should be removed as soon as possible. If the hazards are fixtures, they should be clearly marked and included in safety briefings and with yellow or orange markings.

Making Repairs

Keeping the press in good shape is not only good for business, it is essential for keeping employees safe. Machines that have missing safety guards or tendencies to malfunction are ticking time bombs. Managers, shift leaders and supervisory personnel must take safety as a number one priority including all employees who work around the press. If equipment is not functioning properly, it is everyone’s responsibility to submit a work order for repairs. Progressive metal stamping company supervisors should also have the authority to stop work until the completion of a repair. No timeline or due date for a custom metal stamping project is more important that the safety of an employee. If you work for a metal stamping company in Pennsylvania, you probably have an independent 3rd party that helps oversee the safety environment of your metal fabrication shop.

Press safety and maintenance are inextricably intertwined. For stamping companies that are committed to reducing injury, there is no substitute for a safety and maintenance plan.

Advantages of Working With a Progressive Metal Stamping Partner

Now that your design is ready for fabrication, choosing the right metal stamping company can become a critical step in the production process. Consider the many ways in which partnering with a large metal stamping company may be advantageous.

Cost Savings

Cost considerations may be important to marketability of the final product. Large metal stamping partners may be able to share cost savings without compromising quality.

1. Setup Costs. Rather than paying for setup on multiple machines, long run stamping machines may save costs due to one comprehensive setup process. Particularly for smaller runs, reducing setup costs can make a significant impact in the product’s final cost.
2. Bulk purchases. The larger the partner, the bigger their bulk pricing discounts may be due to the quantities of raw materials they purchase.
3. Shipping costs. Larger metal stamping companies may be able to manage more sections of the manufacturing process without passing the product onto another vendor, which can save in shipping and handling costs.

Speed to Market

1. Multiple Forming Stages in One Pass: If your metal part requires multiple metal forming stages to occur, using a progressive stamping die may be the way to go.
2. Processing efficiencies. Progressive stamping presses feed sheet metal from a coil rather than lifting precut sheets into the press, reducing downtime between processes.
3. Availability of materials. Companies that regularly handle larger stamping runs may have on hand a broader inventory of materials, reducing wait times for raw material delivery.
4. Longer runs. The price per part costs are often significantly reduced in the progressive die stamping process. Ultimately you will need to sell what you produce so over production is not wise. Accurate forecasting is the key to managing production sizes.

State-of-the-Art Technology

Larger fabricators are more likely to invest in CNC technology that improves quality and productivity. Quite often progressive metal stamping economies can be found in the form of automation. Material handling and press set up is what takes workers the most time and there are lifts, automated die inserters and other automated solutions that speed up the production process.

Best Value for the Money

So the best value for the money comes when partnering with the larger metal stamping companies in PA who can provide manufacturing services that improve the production speed as well as lower costs. When you have product sales over 10K units in a given year, progressive metal stamping tends to be the better manufacturing process to lower metal part costs. Long run stamping companies are limited with only a few good options is Pennsylvania.