13 CRITICAL STEPS

to Ensure Metal Stamping Success

HOW METAL STAMPINGS CAN MAKE A
BOTTOM-LINE IMPACT
OEMs that incorporate metal stampings in their products range from medical
device and electronics manufacturers that need micro-miniature parts made from
extremely thin material to automobile manufacturers requiring components made
of high strength steel alloys. The insert molding industry also requires complex
metal stampings that deliver high performance and tight tolerances. Although metal
stamped parts may appear to be just a small component of the larger product, they
can have a significant impact on a manufacturer’s bottom line in terms of costs, cycle
time, and product reliability.

When designed and produced in the most cost-effective manner, metal stampings
can help reduce product costs, cut production time, and enhance product life.

This e-book explains 13 steps that OEMs can follow to ensure their
metal stamped part will perform to their exacting specifications.

1
Step 1: GET IT RIGHT FROM THE START

If engineers at metal stamping firms had just one wish to
make the process go more smoothly it would be for the
manufacturer to involve them very early in the part
design process. Often times, CAD drawings are unrealistic and
don’t take into account the limitations of metal stamping.
In fact, the metal stampings that perform best are based on
Collaborative Product and Process Design, which allows the
metal stamper to interpret the client’s specifications in light
of optimal metal stamping design and production, including
assessment of materials and part tolerances.
as reconfiguring a part to eliminate unnecessary steps in the
overall manufacturing process and drive down expenses.
For example, one large manufacturer brought in
representatives from all of their outside suppliers involved in
producing a key component, including molders, stampers and
electronics specialists, to design the parts as a team. As a
result, the metal stamping was redesigned to make the part
less expensive to produce and easier to assemble.

Metal stamping engineers may propose design improvements

that lead to significant savings in production time and expense
– from something as simple as changing the way parts are
packaged to save on assembly costs to complex changes such

2
Step 2: FORECAST YOUR REQUIREMENTS

It is best to be upfront about your anticipated requirements Your anticipated production volume has a bearing on how a
for the part and its final assembly, including your projected stamping is produced and its cost. Low volume products do
volumes and release frequency for the year. Talk to your not require as robust tooling as do high volume products.
stamper about the impact shipping frequency may have on
overall costs. Manufacturers are often surprised by the amount of lead time
required for a metal stamping. Although rush projects can
If you share the full scope of the manufacturing process from be handled in a matter of weeks, a realistic manufacturing
how you assemble parts through the final assembly, the schedule should allow several months for part design
metal stamping engineers may be able to propose changes review/modification, tool design, material orders, and
or redesign the metal stamping to reduce part cost and make production ramp-up.
it easier to manufacture. If the metal stamping engineer
understands your assembly process, the part may be designed
with features that will save on additional handling. For example,
a metal stamping can be designed to stack at the press in the
orientation you need to prevent secondary handling and
reduce costs.

3
Step #3: EVALUATE CRITICAL TOLERANCES

Tolerances in metal stampings are the permissible variations

from a specification for any characteristic of the part, which
can be a point of misunderstanding with manufacturers.
Some OEMs will specify the tightest tolerances as a general
rule, with the idea that tighter tolerances are always better
and reduce the risk of part failure. However, the tighter the
tolerance, the more expensive the part is to produce, because
the metal stamper will have to spend more time developing
the die and maintaining it to specifications. Of course, a good
metal stamper will be able to achieve tight tolerances and high
precision when required.

Manufacturers and metal stampers should work together to

understand the importance of tolerances in metal stampings
and how much variance will work for the part’s production
process and end use. The metal stamper’s engineers can
collaborate with the OEM’s engineers to determine the most
critical areas of the part, as it relates to form, fit and function,
and determine appropriate tolerances based on those criteria.

4
STEP #4: ASSESS THE DIMENSIONS FOR FINAL ASSEMBLY

Equally important is determining the appropriate

dimensions of the part, and how the part will fit into its final
assembly. If the metal stamping has to mate with another part
or snap into place, those dimensions are critical. Any critical
dimensions should be assigned accurate measurements and
highlighted on the drawing.

To speed the time to market, the metal stamper may be able

to design and run in-die assemblies to eliminate unnecessary
steps in your overall production process and cut expenses.

In order to ensure that the part will function as required,

the metal stamper will follow the requirements for the part
approval process.

5
STEP #5: SET ACCURATE PRODUCTION VOLUMES

Whenever possible, manufacturers are advised to set

realistic annual production volumes at the outset. If you
expect variations in volume throughout the year, the metal
stamper will need to be prepared for a flexible schedule. The
manufacturer also may want to build up an inventory of parts in
advance to meet demand forecasts.

Anticipated production volumes, together with the unique

characteristics of the part, will determine whether you need
manual assembly requiring specialized skills or fully automated
or robotic-assisted assembly of multiple components. For a
new product launch where demand may increase quickly, you
may find it more cost effective to start with automation, rather
than move from manual to automated production and incur
additional costs. If volumes exceed expectations, the metal
stamping firm may need to build a second tool to handle the
extra volume. It is extremely important to share production
volume upfront to determine whether a multiple up-die may
be necessary.

6
STEP #6: SELECT THE BEST MATERIAL AND
MAXIMIZE ITS USE

Manufacturers may specify materials in their request for
quote without fully understanding how the material will
react during the stamping process. The metal stamper’s
engineers can assist in selecting the best material for the part’s
long-term function and wear, based on their knowledge of the
characteristics of a wide range of materials used for different
applications, from beryllium copper to pre-plated alloys to noble
metals. Different materials can be tested during prototyping
and simulation to validate performance.
The standard lead time for most material orders is 10 weeks.
With noble metals and high-demand metals such as copper,
lead times for orders can stretch as long as 12 weeks or more,
which needs to be accounted for in production schedules.
Global lead times for materials, which vary greatly from Europe
to Asia, must also be taken into account.
exact same dimensions. However, with the different properties
of plastic versus metal, the part had to be redesigned as a
drawn component.
In addition, the metal stamper can nest the parts to significantly
reduce the amount of scrap generated in the blanking operation.
The stamper may also make recommendations to save on
material cost by slightly changing the design and not the
function. The stamping engineer can also lay out the part to
minimize the use of precious metals or recommend the use of
spot plating to reduce precious metal costs.

The type of material selected depends on the part’s end

use and the amount of wear the part will experience. One
automobile manufacturer wanted to replace a plastic part that
was being damaged in car washes with a metal part of the

7
STEP #6: SELECT THE BEST MATERIAL AND
MAXIMIZE ITS USE (CONTINUED)

MATERIALS USED IN METAL STAMPINGS

Ferrous metals, which contain iron, are magnetic and have Noble and other metals – which resist oxidation
little resistance to corrosion: and corrosion:

• Hot-rolled and cold-rolled steel • Titanium - this is a non-ferrous material

• Stainless steel • Gold
• High-tensile steel • Platinum
• Low, medium and high carbon steel • Iridium
• Spring steels • Niobium
• Coated steel • MP35N

Non-ferrous metals –­­ which contain no iron and are more Other materials:
resistant to corrosion:
• Mylar
• Aluminum • Plain wire
• Copper • Shaped wire
• Aluminum-clad copper
• Aluminum alloys
• Brass
• Phosphor bronze
• Beryllium copper
• High nickel alloys

8
STEP #7: PLAN FOR SECONDARY OPERATIONS

Plan ahead for plating and other secondary operations Finishes:

and rely on the stamper for guidance and oversight of
the process. These operations should be scheduled so that • Plating
they can be handled as soon as possible after stamping to xx Pre-plating
speed cycle time. The metal stamping firm can be expected xx Post-plating
to oversee secondary operations and quality control on the xx Spot plating
manufacturer’s behalf. xx Precious and non-precious metal plating
• Painting, e-coat and other finishes
SECONDARY OPERATIONS
Assembly:
• Heat treating
xx Loose piece • Manual
xx On reels • In-Die
• Secondary tooling to trim parts or to form and cingulate
at the customer location
• Welding and spot welding
• Mechanical finishing, including sanding, grinding, polishing
and buffing
• Forming and laser welding
• Specialty cleaning and deburring
• Passivation
• Sterilization
• Electropolishing

9
STEP #8: EVALUATE SIMULATIONS AND PROTOTYPES

Manufacturers should take advantage of a metal stamper’s
ability to provide 3-D part simulations and prototypes to
improve manufacturability and reliability, when required.
These capabilities allow manufacturers to test the design and
functionality of component parts before investing in
full production.
costly problems during production and manufacturing. If
the cost of a prototype seems prohibitive, the stamper can
sometimes use simulations to evaluate the part design
functional strength requirements and to optimize the part
design to best suit the metal forming processes.

The prototype will be based on the latest design and prints,

along with material specifications. The metal stamper can
build a prototype tool to validate design, as well as employ
simulation software to evaluate how the material forms under
different conditions to produce the part. If the prototype/
simulation process reveals weaknesses, the tool can be
redesigned to improve function, strength and manufacturability.
Although extra costs are associated with prototyping, this
step can be completed in just a few weeks and often prevents

10
STEP #9: PICK THE BEST PACKAGING

Consider the importance of packaging as it relates to the Packaging Options

final assembly. The optimal packaging will depend on the
• Reel to reel
characteristics of the part and how it will be used on the
• Loose piece
assembly line. Some parts can simply be dropped into bins
• Parts supplied on a bandolier
as loose pieces while others should be packaged on a strip
• Labeling and bar coding
for automated assembly at the manufacturing plant. Parts
• Reusable packaging
that might get tangled must be packaged for easy access. In
• Special handling containers
the same way, delicate parts that must maintain their exact
• Custom packaging
dimensions should be packaged to avoid damage in transit or
• Export services
in handling for assembly. Cost considerations often dictate
• Tape and reel
packaging, but the overall costs of shipping, handling, storage
and processing must be taken into account. In addition, if the
parts will be shipped out of the country, customs and export
services will impact packaging requirements.

11
STEP #10: BUILD IN TIME FOR TOOL DESIGN

Allow time for tool design and development in the The technology that metal stampers may employ in the
production schedule. Ideally, the stamper will have in- design and build stage includes:
house tool design and build capabilities. Manufacturers may
• 3-D tool design and simulation software to develop
be surprised to learn that it may take anywhere from 8 to 26
complex tools
weeks to create a custom tool depending on the complexity
and development of the part. • In-die sensor technology to ensure consistent quality and
reduce downtime
Metal stamping engineers will take the manufacturer’s
production requirements and key characteristics of the part into
consideration when recommending the right design, taking
into account the intended life of the program.

12
STEP #11: PLAN FOR QUALITY WITH APQP

A metal stamper concerned with quality will follow the in the ISO 13485 standard for medical device manufacturers,
APQP (Advanced Product Quality Planning) process or a including Design Qualification (DQ), Installation Qualification (IQ),
similar process to ensure quality from the outset. Operational Qualification (OQ) and Performance Qualification (PQ).

The APQP process was developed by automotive The initial quality planning phase adds time to the schedule but
manufacturers 
and involves their parts suppliers in every saves quality problems down the road.
step of the development and launch process – from initial
development through product launch and beyond. The APQP
process monitors more than 20 areas before production
begins, such as design robustness, design testing, quality
inspection standards, product packaging, and more.

The medical device industry prefers DQ/IQ/OQ/PQ, which

relates to verification and validation of both design activities
and manufacturing process development 
to ensure that the
device will function as specified. The processes are spelled out

13
STEP #12: MONITOR QUALITY IN REAL TIME

Zero defects has become the norm globally. To ensure Quality Control Technology in Metal Stamping
quality in metal stamping, the firm should employ statistical
• Statistical process control systems
process control systems and in-die sensors to monitor quality
in real time. • Optical vision systems
• Functional gauges and custom gauges
In evaluating a metal stamping supplier, ask for an overview of
• Digital measuring machines with metrology software
the technology in place to ensure quality and how frequently
that equipment is used. The best metal stampers will employ • In-die detection systems
quality control processes to detect potential problems in real • In-die measurement systems
time. Manufacturers can ask for quality reports as needed.

14
STEP #13: KEEP IN CONTACT

It may go without saying that it pays to stay in close

communication with the metal stamping firm. If you see
the potential for changes in production volume down the road,
it helps to alert the metal stamper to the possibility and talk
over what preparation might be required.

A customer-focused metal stamping firm will assign a

project manager/engineer as a single point of contact for
all new programs. During production, a customer service
representative would be assigned who knows the customer’s
industry and unique business requirements. Once production
is underway, it is advantageous to work with a customer
service representative who understands the client’s industry
and unique business requirements.

15
THIS GUIDE WAS DEVELOPED BY
KENMODE PRECISION METAL STAMPING

About Kenmode Precision Metal Stamping

Since its founding in 1960, Kenmode has built a reputation for strict adherence to uncompromised
quality and performance standards in the manufacture of complex, high-precision custom metal
stampings and assemblies for the automotive, electronics, consumer goods, insert molding, and
medical device industries worldwide. Today, Kenmode fields one of the largest and most experienced
engineering, design, and tool & die teams in the industry and employs the latest technology
throughout the metal stamping design and production process. Kenmode handles a wide range of
metal stamping materials and component parts, from micro-miniature medical stampings to large
automotive stampings made from steel.

Kenmode
820 West Algonquin Road
Algonquin, Illinois 60102-2486

Tel: 847-658-5041
sales@kenmode.com
Kenmode.com
©2015 Kenmode