Metal stamping is a manufacturing process that transforms sheet metal (primarily in a cold state) into complex parts using custom dies and stamping presses. This method enables the mass production of components across industries.
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Metal stamping basics
Stamping – also known as pressing – is perhaps one of the most automated and cost-effective ways to mass produce sheet metal parts for markets like automotive, EV, HVAC/R, lighting, consumer goods, aerospace and more. Today, the global market for metal stamping is over $220 billion USD (2024) and growing.
Metal stamping is a highly efficient manufacturing process that uses custom tooling and pressure to shape flat sheet metal into finished parts. It’s efficient because it’s mostly automated and requires little to no labor once the tooling is created and set up.
Metal stamped parts
How does metal stamping work?
The power of metal stamping lies in its speed and efficiency. Here’s how it works:
- Die design & engineering: CAD models are developed, and tooling engineers design dies that reflect the part geometry and tolerances.
- Tool making: Dies are manufactured using hardened tool steel. These dies can include multiple stages for progressive or transfer operations. See the benefits of in-house toolroom.
- Press setup: Dies are installed into stamping presses, and coil or sheet metal is loaded for continuous feed or blank transfer.
- Stamping operations: Each press stroke performs shaping, cutting, or forming actions at high speed.
- Secondary operations (optional): Parts may have secondary options, such as deburring, finishing, assembly, or packaging depending on the end-use.
Metal stamping processes
There are several stamping process types, each offering advantages depending on the shape, size, and complexity of your part.
1. Compound die stamping
2. Drawing and deep drawing
Used to produce parts with depth like pot lights or kitchen sinks. The metal is drawn into a cavity to form a seamless hollow shape.
3. Progressive die stamping (most common)
4. Transfer die stamping
Parts are separated from the strip and transferred between stations or adjacent presses. Offers more flexibility and space for complex 3D forming, but also requires higher volumes to justify. Often used for larger or deep parts that can’t be processed in-line.
Metal stamping operations
- Blanking – Cuts a flat shape out of sheet metal. This is often the first step in the stamping process.
- Piercing – Creates holes or cutouts in the metal using a punch and die.
- Bending – Deforms the metal at an angle.
- Coining – Compresses metal within a confined area to create fine details.
- Drawing – Pulls metal into a cavity or over a form, to create depth, often used for cylindrical or box-shaped parts.
- Lancing – Cuts and bends a tab in one operation, still leaving it attached to the surrounding part.
- Embossing – Raises or depresses sections of the metal to create surface features.
- Notching – Removes material from the edge or internal sections of a part.
- Flanging – Bends the edge of a part to create a rim or lip.
- Curling – Rolls the edge of a part into a smooth loop or hook.
- Shearing – Cuts the sheet metal without forming, usually as part of blank separation.
- Trimming – Removes excess material or flash after forming processes.
What metal parts can be stamped?
Metal stamping is used to produce a wide range of parts across industries such as:
- Lighting: IC boxes, plaster frames, driver boxes, bar hangers
- HVAC: grills, mounting plates, duct brackets, structural frames
- Electronics: housings, enclosures, chassis panels
- Automotive: clips, covers, washers, body components
- Consumer goods: brackets, mounts, backplates, appliance components
Materials commonly used are cold-rolled steel, galvanized steel, stainless steel, aluminum, copper, and brass.
When should you consider metal stamping?
Not every production run justifies the upfront cost of tooling, but once you hit a certain volume threshold, metal stamping becomes the most efficient way to produce sheet metal parts.
Metal stamping is the right choice when:
- Small parts can’t be safely handled
- Your annual part volumes are growing
- Tolerances and consistency are critical
- Want to drive down per-unit costs
- Parts have a repeatable design
- Meet regulatory compliance (e.g., UL, NEMA, etc.)
Metal stamping costs & ROI
Custom tooling is at the heart of the stamping process. While it adds upfront cost, it quickly pays for itself by reducing per-part pricing by speeding up production.
What is a stamping die?
A stamping die is a hardened steel tool that cuts and forms your part in a press. Dies can be simple (compound) or complex (multi-stage progressive or transfer).
How much does a stamping die cost?
- Simple dies: $3,000 – $30,000
- Complex dies: $20,000 – $200,000 (or more)
Costs depend on part size, complexity, number of operations, and volumes.
Metal stamping ROI
Metal stamping can drastically reduce part costs by 20% to 80% (or more) vs other sheet metal manufacturing processes. These savings come from faster production speeds, low labor costs, and efficient use of material.
For example, if a CNC part costs $15, stamping could lower it to $3–$12 depending on volume and complexity. For a 100,000-part run, that’s a savings of $300,000 to $1.2 million annually. These reductions not only cover tooling costs but also improve profit margins on every order.
The benefits of metal stamping
With the right application, metal stamping delivers unmatched value compared to most other sheet metal manufacturing processes.
- High speed: Hundreds even thousands of parts per minute
- Consistency: Extremely repeatable results with tight tolerances
- Scalable: Ideal for tens of thousands to millions of parts
- Cost effective: Lower per-part cost with higher volumes
- Material efficiency: Less waste compared to CNC fabrication processes
- Regulatory compliance: Meets strict quality and safety standards
Conclusion
Metal stamping is an automated and scalable manufacturing process for OEMs and businesses looking for precision, repeatability, and cost control. With the right design, tooling, and production partner, you can significantly improve unit economics while ensuring consistent product quality.
