Nine Critical Mistakes to Avoid in Precision Metal Stamping Design -- An Insider's Guide

Richard W. Dennis
Tim Zeigler

Copyright 2008 Die-Tech, Inc.

This document may be duplicated and transmitted for informational purposes.
All copyright notices must be left intact.

Die-Tech, Inc.
295 Sipe Road
York Haven, Pennsylvania 17370
 The 9 Critical Errors to Avoid in
Precision Metal Stamping Design
Years of helping people bring their products to market have show that there are
common critical errors made in precision metal stamping designs that then have
to be corrected and pushed back upstream to the end user once the stamper has
had a chance to assess the design.

Our experience indicates that typically the stamper is introduced to a new

production design after 30 to 40 engineering hours are already invested in the
process, and that the design had already been shared with the end customer
prior to the stamper’s involvement.

The following are the most common critical errors that we see as precision metal
stamping manufacturers, and we wrote this insiders’ guide to help those charged
with designing metal stampings avoid these common issues that waste time,
energy, and effort.

It is vital to be aware of these nine critical errors to avoid that trip to the customer
we all dread: you know the meeting where you have to explain why the “revised”
design is going to work so much better than the original concept shown to them.
And we even added a bonus for you at the end – the tenth most critical thing to
know when you design precision metal stampings, the one you surely want to
avoid.

Critical Error #1 -- Failure to Understand that Tolerances Cost You Time

and Money

Tolerances, the permissible limit of variation in the physical dimension of a part,

can greatly impact the cost of a part and the progressive die that produces it. By
specifying tighter tolerances than necessary to maintain proper product
functionality, your stamping manufacturer will be forced to spend more time and
money developing and maintaining the die. Since die development can be 40%
of initial progressive die cost, the tolerances you assign to any given dimension
will impact the price you pay for that die. Maintenance costs are expressed in
the part unit pricing and are incurred for the life of the program.

To determine appropriate tolerances one must understand the end application for
the stamped product and how those stampings are expected to interact with
other parts in the assembly. Then one can decide how tight tolerances may be
on any given area of the precision metal stamping without impacting other factors

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
Page 2 of 10
or the outcome of your entire assembly. Fit and function for key areas of the
stamping should be what drive the tolerance specifications, and other non-key
areas should have a wider tolerance to help minimize costs and ease production.

Tooling wear during the stamping process involves inherent variation in the parts
produced. The tolerances selected must be compatible with the normal tool wear
for the type of raw material being used for the stamping to prevent higher costs
associated with more frequent tool
maintenance.

Lead time, too, can be impacted by the

tolerances specified on a stamping. For
example, as much as one week can be
added in the die development phase due to
tight tolerances. Regularly, getting product
to your customer is on a very tight time line
and adding one additional week to product
lead time could possibly make or break
your advantage over your competition.

So what is the norm? Tolerances set at +/- .001 when cutting a flat shape out of
metal offer no challenges for long tool life and die development. They are just
business as usual. Formed stampings (those with curved, curled or bent areas)
can be specified with tolerances of +/- .003.

Critical Error #2 -- Neglecting to Differentiate the Dimensions that Matter

Dimensions critical to the application are what matter the most in a precision
metal stamping design. Interactive mating components such as connector-to-
connector mating, mating within a housing, or multiple pressure points for a snap
fit, are the dimensions that allow your assembly to run smoothly or cause it to
have a major melt-down on the manufacturing floor.

Start your process by defining the key characteristics for the assembly process,
key characteristics for the end product, and most importantly, full understanding
of the key characteristics in the eyes of your customer. Focus on the surfaces or
features that must mate or align with other components or assembly equipment
and define tolerances for those critical dimensions. Allowing wider tolerances on
the non-critical dimensions will save development time for the progressive die
and keep a lid on part and die pricing.

Then, be sure the dimensions selected as critical can be readily measured and
are clearly noted on drawings.

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
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Critical Error #3 -- Failing to Look Ahead

Manual assembly allows for fewer critical dimensions and often is the starting
point for many projects. However, what happens if your product really takes off
in the marketplace? Unless you are producing for an industry known for short
runs (for example -- a toilet seat in a space shuttle), it just makes sense to design
the part with future automation in mind.

Determine how the product will be handled as it moves through prototype, small
volumes to high production runs. Then consider what components or features
could be built into the precision metal stamping from the start to reduce handling
or eliminate secondary operations.

Carrier strips, clips, springs, boxes, tubes, connectors, snaps, or a secondary

disposable stamping often allow automated equipment to run at higher
production speeds and saves the capital investment in apparatus such as feeder
bowls. Keep in mind that frequently features in the stamping or its carrier strip
can allow you to use the stamping as a fixture in the assembly equipment.

For example, a nationally known manufacturer of filters for microwave

communications operated an assembly line for hand insertion of chem-etched
parts which created poor quality filters and a labor intensive process.
Collaboration on the compliant stamping eliminated assembly damage and
simplified fit tolerances. Follow up automation resulted in restoring a major
product line to profitability for the microwave filter producer.

An automated process increases through-put rates and produces a more

consistent product for your customer. And while it may make sense to start with
a manual production process, as demand for your product ramps up manual
operations may add up to as much as 70% of your production costs.

Critical Error #4 -- Blunders in Packaging Selection

Loose piece in bags, loose piece in trays, product on reels; what is the best
packaging of the precision metal stampings for your assembly process?

While it may seem easiest to just stamp your product and have it drop as a loose
piece into a bag or barrel, there are other options that probably make more
economic sense. Once you have control of a part, why give it up? Sorting
stamped components back into a specific order will cost a small fortune over
time.

Secondary processes after the part is stamped are usually enhanced by keeping
the metal stampings on its carrier strip (a carrier strip is the portion of the original

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
Page 4 of 10
raw material strip that enables product to be indexed through the progressive
die). For example, plating loose parts may damage critical features as they roll in
the plating barrel, and shipping loose piece parts in a box or bag allows them to
‘nest’ together with the resulting damage involved in getting them pulled apart for
assembly.

Stamping is rarely the last step in your application. Does your stamping need a
plastic over-molding? Does it need to be processed with plating in mind? Does
it need to function flawlessly in automation equipment?

Keeping precision metal

stampings attached to their
original carrier strip and
packaging them on reels
offers control of orientation for
automation, permits specialty
plating such as gold tips, and
enhances secondary
processes such as heat
tempering, solder application,
or spot welds.

Critical Error #5 -- Ignoring Strip Progression

Strip progression is the order in which a die progressively cuts and forms the
metal stamping. Typically designers of precision metal stampings don’t concern
themselves with strip progressions since orientation of the product is usually
controlled by the grain direction of the metal. However, if quoted prices seem to
be high it makes sense to take a look at the proposed strip progression as it
relates to raw material usage.

The layout of the progression on the metal strip can impact your costs by as
much as 50%. It is not unheard of to even save 80% of your metal costs with a
different orientation or by inter-digitation of parts.

An example of this: a manufacturer in the mid-west had designed a part with a

large circle of raw material in the center that was going to be scrap. After some
discussion with our lead engineer, it was determined that the circle of raw
material that would have been waste from that first part was large enough to
produce a second part they were going to tool later that year. Two different
products from one progressive die, and raw material cost savings at the same
time – really a win, win situation.

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
Page 5 of 10
Critical Error #6 -- Alloy Selection Mistakes

Application, application, application. Application requirements drive the selection

of raw material used in a precision metal stamping. Do you need spring
characteristics in a formed part? Then you probably want to use a beryllium
copper, some type of steel, or a hardened phosphor bronze such as alloy 510.
Brass has poor spring characteristics, but works well for flat stampings.

Using stainless steel for your stamping can eliminate plating costs while
providing corrosion control and is used most often in medical and automotive
applications. More exotic materials can be stamped for high-temperature
applications.

Often electrical or molding needs impact your choice of alloy. Manufacturers of

the various metals provide charts of electrical conductivity as well as thermal
conductivity and the coefficient of thermal expansion to help you with selection.

Generally a stamping manufacturer has a core selection of metals they stamp

most often. They can help lower your costs by combining your metal
requirements with others in bulk orders from the rolling mill. Ask your stamping
supplier for recommendations once you understand the demands of your specific
application.

Critical Error #7 -- Miscalculations in Plating Selection

Did we mention how important application is to the entire design process?

Plating addresses a need in the application – usually to prevent corrosion of the
base material used for the stamping. Since the advent of the European
standards for electrical components (RoHS) in July, 2006, the global market
place has moved away from plating that contains lead. What’s left is basically
tin, gold and nickel. Each of these has their short-comings.

Tin when plated or reflowed at low currents grows whiskers and can short out
your device when connections are bridged by these growths. Gold is expensive
and tends to be absorbed into the base metal so typically requires that a flash of
copper or ductile nickel be applied to the base metal prior to gold plating. Pre-
plated nickel tends to crack when used in applications that have forms or spring
characteristics.

So, what is the best option for your application? An exceptional metal stamper
will be working hand-in-hand with quality platers that can assist you in the
selection of the best solution for your project.

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
Page 6 of 10
 Then there is the decision of pre-plating (the raw
material is plated before the part is stamped) or post-
plating (the part is plated after it has been stamped),
loose plating, rack plating or strip plating. If all sides of
your part need to be protected, post-plating is your only
option. But if your application allows for the raw
material to be exposed on the sides cut by the stamping
die, then pre-plating is a cost saving option.

Critical Error #8 -- Sharp Corners, Burrs & Thinking

that Twist, Camber, or Coil Set won’t affect Fit,
Form, and Function

Some designers and users of precision metal stampings spend a lot of time
worrying about twist, camber and coil set and how they impact fit, form and
function of the metal stamping in their assembly process. The reality is that any
stamper worth their salt deals with these issues in the design of the progressive
die and you should never have to address these issues.

Clear communications with your stamping manufacturer concerning the end

application for the product is your best defense against the challenges of twist,
camber and coil set. Let the stamper do their job with adequate application
information and these three become non-issues. On the other hand, if you are
constantly dealing with this trio, perhaps it is time to re-evaluate your company’s
choice of stamping supplier.

Sharp corners are just not a fit for progressive metal stamping. While it is
possible to have dead sharp corners using a progressive die, it shortens the tool
life from thousands of hits to approximately one hundred hits. Shorter tool life
equals higher maintenance costs, thus increasing part price. If your product
requires dead sharp corners, you need to consider an alternate manufacturing
process such as fine blanking. However, if your application can accept corners
with a radius of .005 or greater, progressive stampings dies will do the job.

Ordinary stampers run with burrs that are 15% of the base metal thickness, and
then coin the edge to move the burr to the side of the part, or tumble loose piece
stampings in a barrel with slurry that removes the burr, an added expense.
Extraordinary metal stampers use cutting clearances in their tooling that produce
minimal burring that does not need to be coined or removed – typically 3 to 7 %
of the base material thickness.

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
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Critical Error #9 -- Not Using Three Dimensional (3D) Modeling

Not using 3D modeling can hamstring your design and production efforts. It
plays a big part in being able to visualize and understand the relationships of
angles, bends, and the critical dimensions of your stampings -- and how they
relate to the other components in the final assembly.

Working with 3D modeling allows for almost instantaneous changes or updates in

the design of the product. It also removes many communication barriers
between your facility, your customer, the metal stamping manufacturer, or any
other service provider in the process (such as the plastics molder).

BONUS: Critical Error #10 -- Not Being Prepared for when Things Get Ugly

You have worked to ensure your precision metal design eliminates the nine
critical errors described above, and started the process of selecting a stamping
partner to help bring this design to reality. But how can you be sure you are not
selecting a precision stamping manufacturer that will sink your efforts?

Here are a few red flags that indicate you have found a run-of-the-mill stamper:

x They seek your business at any cost – quoting jobs that don’t
really fit their capabilities
x Their procedures and quality policies look good on paper but don’t
seem to exist outside the quality manual
x Employee turnover at the supplier is high and you keep having to
explain your requirements to a new contact
x Your purchasing department complains about constantly pushing
to get product -- no Kanban or ‘pull’ system is available for
product management
x They don’t require a contract, relying on purchase orders and
mutual mystification should the project change course
unexpectedly
x Customer service personnel are not actively keeping you in the
loop as issues arise.

If any of these bullets are familiar to you, it may be time to hunt for an exceptional
metal stamper because having the right precision metal stamping partner will
make all the difference to the success of your program over the course of its life.

Working with a partner that understands the metal stamping discipline as it

relates to the entire assembly process will ensure a well designed product that
takes advantage of the ability to integrate fixturing, handling, locating, and
orienting features that should be inherent in a precision metal stamping. Skillfully

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
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designed stampings make the difference in the quality, consistency, and
manufacturability of any product that incorporates their use. These and other
important factors are often overlooked by the run-of-the-mill stamping
manufacturer.

For example, a leading producer of igniters in

the Northeast invited Die-Tech in to evaluate
the use of precision metal stampings in the
igniter assembly process. They were using
twelve separate components along with a
manual solder dipping operation to assemble
their product. During the collaboration that
followed, a custom designed metal stamping
reduced the number of components from the
original twelve to six and replaced the solder
dipping requirement with a precision dot of
solder paste. The cost savings realized by these improvements alone paid for
the cost of tooling the new stamping and allowed the company to pass along
savings to their customers while maintaining their original profit margin. The
lower price made the product more competitive and enabled the manufacturer to
gain market share.

The Hotline is Open

Once you have established a relationship with the right stamper – one that has
open and honest communications, diverse experience to share, and a lean
operation with responsive customer service -- help them understand your
application, then rely on their experience and advice. This is the ultimate way to
save yourself time, energy and effort.

If you are facing challenges with your metal stamping designs and would like to
explore alternatives, Die-Tech hosts a hotline that is staffed by engineers
Monday thru Friday, from 8:00 a.m. until 4:00. We invite you to call and discuss
your challenges and projects. The hotline number is 1.888.89.STAMP
(1.888.897.8267) or email us: stamping@die-tech.com.

Thank you for taking the time to request and read this insiders’ guide for the
precision metal stamping designer. We sincerely hope it helps make your job
easier.

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
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 About the Authors

Mr. Richard W. Dennis served his formative years in the United States Army where he
served as a member of Special Forces/Airborne. This experience enhanced his leadership
abilities and provided a solid foundation in development and execution of strategy and tactics.
After his honorable discharge from the Army, Dennis earned his a Bachelors of Science in
Recreation and Park Management from The Pennsylvania State University, State College,
Pennsylvania. Following graduation he learned the basics of continuous coil plating while
managing a small plating company in Maryland. This experience lead to the formation of his own
plating company, Leaderplate. While owner and CEO of Leaderplate, Dennis gained the
recognition of his peers and served as a board member and as president of both the Baltimore
Washington Branch, and the Mid-Atlantic Region, of the American Electroplating and Surface
Finishing Society. Leaderplate operated profitably from 1983 until the sale of its assets in 1996 to
Sharrett’s Plating Company at which time Mr. Dennis joined Die-Tech, Incorporated to provide
family leadership to guide Die-Tech into the future. Dennis’ business experience, organizational
style, entrepreneurial attitude and deep commitment to personal, as well as company growth, has
been instrumental in creating the management model which is allowing Die-Tech, Incorporated
to move from it’s founder phase into its’ mature business phase.

Mr. Timothy Zeigler graduated from the Williamsport Area Community College with an
Associate Degree in Machine Tool Technology in 1984. He was hired at AMP Inc as a
progressive die repairman upon graduation. In 1986 Zeigler was selected to participate in the
state approved Tool and Die Maker Apprenticeship program and received his journeyman papers
in 1990. He continued with AMP as a toolmaker until 1994 when he accepted an apprenticeship
in the Model Maker Machine Development group within AMP. While in this apprenticeship he
continued his college education in the Mechanical Engineering curriculum at Harrisburg
Community College and moved into the Engineering Rotation program in the Automation
Engineering Department where he continued until TYCO acquired AMP in 1999. Zeigler came to
Die-Tech as a Metal Stamping Engineer in December of 2000. He assumed his current position
as Vice President of Business Development at Die-Tech in 2003.

R.W. Dennis and T. Ziegler: Nine Critical Errors to Avoid in Precision Metal Stamping, 2008.
Copyright 2008 Die-Tech, Inc. http://www.die-tech.com/newsletters/nine_errors.pdf.
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