The metal stamping process is a service that particularly requires precision, accuracy and point by point execution. Only this approach guarantees a satisfactory level of the component.
Metal stamping is the expertise of Mikrostyk SA; the company specializes in servicing companies and offers complex solutions to them. How does the stamping process look like step by step? The full procedure translates directly into desired effects.
First contact and inquiry
Technical drawing – is the basis of submitting an inquiry, which starts the formal process associated with metal stamping. The drawing must include all data of the component. Key information is the final material the component is made of, specifics of later processing and the tolerance of dimensions. What is particularly significant: the dimension itself – as the experience gained over many years shows – is not a reliable measure. The introduction of tolerance and specific margin allows for greater flexibility and more precise achievement of required assumptions.
Not less important information is the final designation of the product. Builders and technicians involved in the stamping process may therefore draw attention to details. Awareness of where and how a particular element will be assembled allows to suggest possible corrections and make other recommendations.
Mikrostyk SA is not only the production process itself, but also full advisory – the broader knowledge about individual components and their application, the better the possibility of professional advice. This has been proved with the examples of the past – the knowledge that a particular product will constitute, for example, a piece of the outer casing will cause that its surface will be specifically verified for possible minimal post-production scratches.
After an analysis of the needs, it’s time to prepare the calculation. Here not only a competitive price is important. More and more significant is the so-called lead time, which is the time of the project implementation. Quality of service is also of great importance. All these elements make up the final offer for the customer, which – obviously – is negotiable. All details are always tailored to the recipient’s specific needs and capabilities. This process is finalized by placing an Order.
Construction of a specified tool
The end of the first stage of documentation is a green light for the work of tool builders. Now they can start the construction of a tool that, after inserting in the press and feeding the metal strip, will punch the desired component. At this stage it is once again significant to emphasize the importance of the builder’s knowledge about the application of the component. Designation, function, design – all this is important for the final product evaluation. The tool must also be constructed so that it can be easily modified if there’s such need in the future.
The whole process – in terms of raw materials and logistics – rests with Mikrostyk, of course. The supply department provides relevant materials; their specification is fully consulted with the customer. The customer usually relies on the supplier’s expertise and experience; however, there were some projects during which the customer presented specific requirements for tools – stamps, matrices, types of metal sheets. Of course, such solutions are possible – regardless of the option you choose, the purchasing department will search for the best solution for your retail element.
Building tool for metal stamping
Mikrostyk has his own Tool Shop, where each stage of tool development is pursued. Many years of experience gained and hundreds of projects carried out allow the company to provide comprehensive service: from ordering materials from suppliers, punching plates, stamps, dies and bushes to supervision. Subcontractors are solely involved in hardening tool parts. Upon their return, manual processing of elements takes place, e.g. grinding, possible corrections and final assembly of the tool.
Tool testing and prototype production
An important test of the tool quality is its first trial use, which gives the opportunity to verify and introduce changes. This is the element that affects the start of production and the quality of the final product – the prototypes of metal parts that are created in this way are sent to the customer for evaluation. After further suggestions and comparisons, the necessary changes can be made.
Only after the abovementioned trial use, the design is validated – it is essential that the retail product is 100% compliant with the drawings and that the tolerances of the dimensions are fully respected. However, if the product is functional despite the failure to respect the dimensions included in the technical drawing, at this stage the customer may sometimes change the documentation.
Serial production of metal components
The end of arrangements and the verification of the trial use precede the start of serial production. In the first stage, the operator’s and the adjuster’s instructions are followed. The tool is inserted into the press – when the piece is fully compliant with the design, a fully controlled production process begins.
This includes not only the stamping and packaging but also, e.g. crimping, threading, clamping bushes, assembly, degreasing, nickel plating, galvanizing.
It is one of the key elements of production. The control department is based on both human and machine work. In this way it is possible to verify the correctness of punching, pressure or markings. For each retail product, a jig/poka yoke device is created, where you can check elements for dimensions, shapes or placement of holes. This mechanical verification allows to avoid any mistakes that could result from the weakness of the human factor.
Packing and shipment
The produced elements are examined once again – already during packaging the shipment for the customer. It takes place just before putting the products in cartons, on pallets. Then a 100% control of all components for order compliance and visual verification is performed.
Taking care of the details and the comprehensiveness of the services rendered enable us to offer services to an increasing number of our customers.