Progressive stamping involves the creation of an automated metal forming production line that replaces the manual process of carting partially-completed parts from one production bay to the next. Ajax recommends progressive stamping when:
- High quantities of the same metal part will be needed over a long period of time (a “long-run”), resulting in a lower cost per part
- The cost of more elaborate tooling can be justified
- Multiple cutting and forming operations (“hits”) are required to produce the part efficiently
- Many parts are needed within a short timeframe, forcing quick set-up
- The part must conform to very tight tolerances with few NCs (non-conforming parts)
- High press tonnage is required to produce the part
Ajax has a long history of engineering progressive stamping solutions that speed production, minimize non-conforming parts, and keep costs as low as possible. Check out this progressive stamping success story featuring hardware insertion.
In-house tooling enables Ajax to create, test, maintain, and store stamping tools quickly and cost-effectively. This in-house capability avoids third-party tooling, which can add significant time and overhead to a project.
Ajax offers the latest tooling technologies and professional expertise for die design and build, such as Logopress3 for SOLIDWORKS™. Our solutions range from fully progressive, high volume to low cost, short run.
We build progressive stamping die sets that require the lowest possible human interaction, helping to keep labor costs in check. All our progressive dies employ die-set electronics. These sets of die protection carry many purposes, including part quality and prolonged die life.
The animation below shows the various components of a progressive stamping tool and die setup.
The in-house tooling capability at Ajax also enables us to innovate tooling solutions that solve complex metal forming problems at a cost point that makes sense. That’s an important reason why Ajax has been able to form long-lasting relationships with our customers
In addition to tooling, Ajax offers expertise in material selection and design for manufacture. Our specific area of expertise is creating stamping production plans that save time and material costs for our customers.
OEMs come to Ajax for one-time short runs as well as standing orders of millions of parts per year. Our quality and productivity make us globally competitive, with more than a third of our production exported to China, Vietnam, the Caribbean and Europe. Ajax partners with our customers throughout the production life cycle, from tooling design to production to Kanban solutions that reduce inventory costs and lead times.
Ajax can provide assembly services as part of a progressive stamping run. The video below shows a progressive stamping line with hardware insertion running on a 200-ton press.
Progressive stamping is actually a production line. It requires material to be fed into the press at a preset speed and length. Each stroke of the press, or “hit”, advances and forms the metal into a finished part. The finished part is severed from the material strip as a final step in the operation.
A coil of aluminum feeding a progressive stamping line.
Material is delivered into the press via a coil feeding system. The coils are ordered to exact specifications by the Ajax purchasing manager. Coiled material greatly reduces material handling time and simplifies inventory management.