Tripar Blog

Progressive Die Stamping: What it Is and How it Works

April 7, 2025

If you‘re looking for rock bottom prices on metal components, thankfully there’s progressive die stamping. In fact, it’s one of the most automated and scalable manufacturing processes used across industries.

Keep reading to learn about progressive die stamping and how it works.

What is progressive die stamping?

Progressive die stamping is a manufacturing process that produces complex metal parts from a single die setup. It’s called “progressive” because the metal strip progresses through the die into a series of stations, each performing a specific task that gradually forms the part until it reaches its final completed shape.

This process is ideal for mid to high volume production because it combines multiple steps into a single automated operation. Unlike traditional stamping methods that require separate setups for each task, progressive stamping streamlines production, enhancing consistency, quality, speed, and lowers costs. It’s often used across automotive, electronics, lighting, HVAC, and consumer goods to mass-produce metal parts and products.

What is a progressive die?

A progressive die is a custom machined tool used in metal stamping. Each station performs a specific task like cutting, bending, forming or a myriad of other operations or features as the metal strip moves through the die. This continuous process drastically reduces labor costs, increases efficiency and ensures repeatable quality.

A typical progressive die setup

How does progressive stamping work?

In short, here’s how it works:

A metal coil (steel, aluminum, copper, etc.) feeds into a stamping press.
The metal strip moves through a progressive die with multiple stations, at a very precise increment, also known as the die pitch.
Each station performs a specific cutting, bending, forming or other operation, even tapping.
By the final station, the finished part is separated from the strip.
The remaining material is discarded and recycled.
Thus, once the cycle has started, one (or more) finished parts come out of the die with every stroke of the stamping press.

And with presses operating anywhere from 25 to 200 strokes per minute (or more), it’s easy to see how this automated process makes progressive die stamping ideal for mid to high-volume production with repeatable tolerances.

Our client saved $350,000 annually on this part

Type of dies for metal stamping

Here are the types of dies in order of complexity.

1. Single-stage dies

Performs one operation per cycle (e.g., cutting, bending, forming, each done in separate dies.)
Slowest method, used for low-volume or prototype production.

2. Compound dies

Performs multiple operations in one press stroke (e.g., cutting and forming simultaneously).
Best for simple, flat parts needing high accuracy.

3. Progressive dies (most common)

Uses multiple sequential stations.
Efficient for mid to high volume production.
Low labor costs due to automation.

4. Transfer dies

Moves individual parts from station to station (unlike progressive dies, which keep the strip intact).
Better for deeper forming operations like deep drawing.

Top benefits of progressive stamping

Low unit costs– Reduces manual labor and speeds up production.
High precision – Consistent repeatability quality with tight tolerances.
Minimal waste – Optimized material usage reduces scrap.
Fast lead times – Ideal for OEMs needing thousands to millions of parts annually.
Versatile – Used across automotive, HVAC, electronics, lighting industries, consumer goods, and more.

Common applications for progressive stamping

Automotive – Brackets, fasteners, connectors.
Electronics – Battery contacts, enclosures, connectors.
HVAC – Brackets, housings, ventilation parts.
Lighting – IC boxes, bar hangers, plaster frames.
Consumer Products – Appliances, brackets, encasings, etc.

Progressive die stamping costs & ROI

Progressive die stamping can significantly reduce your per-unit costs often by 50%–80% (or more) as compared to CNC processes. Its efficiency comes from building a custom die that performs all production operations with almost no labor.

For OEM manufacturers requiring 20,000+ annual units or more, the ROI is substantial. The upfront tooling die charge can often be recouped in 6 to 18 months. Manufacturers can often save $50,000 to $500,000 annually per part (or more) by switching from CNC to progressive stamping.

How much does a progressive die cost?

The cost of a progressive die ranges from $10,000 to $200,000 (or more) depending on the design’s complexity and requirements.

Drawbacks of progressive stamping

Initial die cost – Requires somewhat of a significant upfront tooling investment.
Not ideal for low volumes – Although CNC laser cutting and punching is more cost-effective for small to mid volume production runs, smaller components that can’t be handled safely must be manufactured by stamping operations.
Limited to certain part geometries – Very complex 3D shapes may require other manufacturing processes.

Conclusion

Progressive die stamping offers unmatched quality, efficiency and scalability—making it a preferred method of fabrication for many industries. If you’re looking to streamline the production of your metal components, Tripar is here to help.