Metal stamping
First contact and inquiry
A technical drawing is the basis for submitting an inquiry, initiating the formal process associated with metal stamping. The drawing must include all data regarding the component; the final material from which the component is made, specifications of subsequent processing, and dimensional tolerances. Introducing tolerances and margins is particularly important, as it allows for greater flexibility and precise achievement of the required parameters. Equally important is information about the final use of the product. Designers and technicians involved in the metal stamping process can then pay attention to details. Awareness of where and how a particular element will be assembled allows for suggestions of possible corrections and other recommendations.
After the technical analysis of the inquiry, it’s time to prepare the calculation. Not only is a competitive price important, but the project’s completion time and the so-called "lead time" for tool construction are also increasingly significant. All these and other elements make up the final offer for the client, which is often modified based on changes that arise in the project from both the client and the client’s customer. We are very flexible and always ready to cooperate. All details are always tailored to the specific needs and capabilities of the recipient. This process concludes with placing an order.
The entire process of raw materials and logistics rests, of course, with Mikrostyk. The procurement department supplies the appropriate materials; their specifications are fully consulted with the designers, technologists, and the client. The client usually relies on the supplier's knowledge and experience; however, there have been projects where the client presented specific requirements for tools – punches, dies, types of metal sheets. Such solutions are, of course, possible – regardless of the chosen option, the procurement department will find the best solution for your metal stamping needs.
Building a stamping tool / die
Mikrostyk has its own tool workshop, where every stage of tool development is carried out. Many years of experience and hundreds of completed projects allow us to offer comprehensive service: from ordering materials from suppliers – such as punches and gas springs, to cutting dies in our CNC department, hardening them (sometimes done in cooperation), and final tool assembly.
Tool testing and prototype production
An important test of the tool's quality is its first trial use, which provides the opportunity for verification and adjustments. This step affects the start of production and the quality of the final product – prototypes of metal parts created in this way are sent to the client for evaluation. After further suggestions and comparisons, necessary changes can be made. Only after the mentioned trial use is the design approved – it is crucial that the product is 100% compliant with the drawings and that dimensional tolerances are fully maintained. However, if the product is functional despite deviations from the technical drawing, at this stage, the client may sometimes choose to modify the documentation.
Serial production of metal components
The acceptance of trial-produced components with the new tool initiates the process of serial production. In the first stage, the technology department creates operator and setup instructions. The tool is then mounted in the press, and metal stamping begins. The component often undergoes additional processes – bending, galvanic treatment (nickel plating, degreasing, deburring), vacuum washing, assembly of nuts/rivets/rubber parts/bushings, crimping, painting, and many others.
Metal stamping - quality control
It is one of the key elements of production. The quality control department relies on both human and machine work. This allows for the verification of the correctness of stamping, pressure, or markings. For each retail product, a jig/poka yoke device is created, where elements can be checked for dimensions, shapes, or hole placements. This mechanical verification helps avoid errors resulting from human factors.
The produced components are re-checked based on the adopted process technology. During serial production, between each established batch, the product is taken to the laboratory for verification as well as during packaging for shipment to the customer. This is done just before placing the products in cartons on pallets. Attention to detail and the comprehensiveness of the services provided allow us to offer metal stamping services to an increasing number of customers.
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