Custom Metal Stampings-custom wire forming-Irvington, NJ-Deeco Metals

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	Custom Metal Stampings & Wire Preforms

Metal stamping includes a variety of sheet-metal forming manufacturing processes, such as punching, stamping, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form or part from the strip or sheet metal, or the part may require a series of strokes through a multiple die/tool. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene. Deeco Metals offers a full range of custom metal stampings in brasses, bronzes, coppers, steels, stainless steels, nickel & Nickel Alloys and aluminum alloys. We specialize in metal stamping processes such as fine blanking, punching, deep draw, progressive die, and modular die.

Our plant’s tooling department is equipped with wire EDMs or Spark Eroding Equipment, CNC machining centers, mills, drills, and lathes to create all stamping tools. Most all our tooling is made in-house and only for our production so we offer very low tool prices. We do not offer tooling for sale.

First article samples from a new die are made available to customers for approval before actual mass production begins.

Deeco Metals’ plant manufactures precision stamping products ranging from telephone components to bullet casings. Our deep draw tooling process is best suited for manufacturing diverse shapes such as cups, pans, cylinders, domes, and products with irregular shapes. Our progressive tooling capabilities allow us to complete high volume projects in short turnaround times.

In addition to metal stampings, we also specialize in manufacturing custom wire-forms or pre-forms in distinct sizes, shapes, and diameters. These parts are produced from brass wire, bronze wire, copper wire, silver brazing alloy wire, steel wire, stainless steel wire, nickel & Nickel Alloy wire and aluminum alloy wire.

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Specifications · Industries Served & Typical Parts · Fine Blanking Process · Deep Draw Process

Specifications

Tooling Capabilities		For our own tooling only Deep Draw Tooling Progressive Tooling Modular Tooling Fine Blanking Tooling Punch Tooling

Workable Metals		Aluminum Alloys Copper & Copper Alloys (incl. Brass & Bronzes) Nickel & Nickel Alloys Stainless Steel Alloys Steel Alloys

Press Tonnage		Various sizes of presses are used and are dependant on part size and material to be stamped.

Tolerance		This varies and dependant on the material and the process. Available once drawings are received and studied.

Value-Added Services		Drilling/Tapping Machining Painting (Topcoat/Primer) Plating (all types) Powder coating & other coatings available in-house or sub-contracted

Order Quantity		From Small Batches to Large Production Orders

Typical Lead Time		Existing tooling 10-12 weeks or sooner. Expedited service is available. New tooling FAS (First Article Samples) 6-8 weeks and after approval production 6-8 weeks

Standards		Our plant is ISO 9001:2000 Certified & Compliant

Quality Assurance		Chemistry Compliance – full certification Hardness, elongation, and tensile strength to ensure high quality in the final metal stampings. Our measuring equipment includes Optical Comparators Since material quality is critical to the performance of strip & sheet metal stamping products, we test all materials prior to stamping. In addition we test for: We also offer Heat Treating

Industries Served & Typical Parts

Aerospace / Aircraft

Agricultural Equipment

Architectural

Automotive (Indirect)

Building & Construction

Business Machine

Commercial Hardware & Equipment

Computer Equipment

Cutlery

Dental Equipment

Electronic Parts & Equipment

Firearms

Fluid Power Devices

Food Service

Furniture

Gaming

Hand Tools

Home Appliance

Industrial Machinery Equipment

Industrial Valve

Lawn & Garden Equipment

Lighting Fixtures

Measuring Devices

Medical Device

Musical Instruments

Office Equipment

Packaging Machinery

Photographic Equipment

Process Controls Equipment

Sport & Recreational Goods

Telecommunications

Toys & Hobby

Transportation Equipment & Supplies

Vending

Fine Blanking Process

Typical fine blanking press cross section

Fine blanking is a specialized form of blanking where there is no fracture zone when shearing. This is achieved by compressing the whole part and then an upper and lower punch extract the blank. This allows the process to hold very tight tolerances, and perhaps eliminate secondary operations.

Materials that can be fine blanked include aluminium, brass, copper, and carbon, alloy and stainless steels.

Fine blanking presses are similar to other metal stamping presses, but they have a few critical additional parts. A typical compound fine blanking press includes a hardened die punch (male), the hardened blanking die (female), and a guide plate of similar shape/size to the blanking die. The guide plate is the first applied to the material, impinging the material with a sharp protrusion or stinger around the perimeter of the die opening. Next a counter pressure is applied opposite the punch, and finally the die punch forces the material through the die opening. Since the guide plate holds the material so tightly, and since the counter pressure is applied, the material is cut in a manner more like extrusion than typical punching. Mechanical properties of the cut benefit similarly with a hardened layer at the cut edge from the cold working of the part.[6] Because the material is so tightly held and controlled in this setup, part flatness remains very true, distortion is nearly eliminated, and edge burr is minimal. Clearances between the die and punch are generally around 1% of the cut material thickness, which typically varies between 0.5–13 mm (0.020–0.51 in).[7] Currently parts as thick as 19 mm (0.75 in) can be cut using fine blanking. Tolerances between ±0.0003–0.002 in (0.0076–0.051 mm) are possible based on material thickness & tensile strength, and part layout.

With standard compound fine blanking processes, multiple parts can often be completed in a single operation. Parts can be pierced, partially pierced, offset (up to 75°), embossed, or coined, often in a single operation. Some combinations may require progressive fine blanking operations, in which multiple operations are performed at the same pressing station.

The advantages of fine blanking are:

Excellent dimensional control, accuracy, and repeatability through a production run.
Excellent part flatness is retained.
Straight, superior finished edges to other metal stamping processes.
Smaller holes possible relative to thickness of material.
Little need to machine details.
Multiple features can be added simultaneously in 1 operation.
More economical for large production runs than traditional operations when additional machining cost and time are factored in (1000–20000 parts minimum, depending on secondary machining operations)

The disadvantages are:

Slightly higher tooling cost when compared to traditional punching operations.
Slightly slower than traditional punching operations.

Deep Draw Process

Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention.

The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. This is achieved by redrawing the part through a series of dies.

Commercial applications of this metal shaping process often involve complex geometries with straight sides and radii. In such a case, the term stamping is used in order to distinguish between the deep drawing (radial tension-tangential compression) and stretch-and-bend (along the straight sides) components. Deep drawing is always accompanied by other forming techniques within the press. These other forming methods include trimming, piercing, bulging, reducing, ironing (wall thickness reduction), rolling or beading (often to create O-ring seats), threading, sidewall piercing, crimping, date or pattern stamping and many others. It common use to consider this process as a cost saving alternative to turned parts which require much more raw material.

Variations
Deep drawing has been classified into conventional and unconventional deep drawing. The main aim of any unconventional deep drawing process is to extend the formability limits of the process. Some of the unconventional processes include hydromechanical deep drawing, Hydroform process, Aquadraw process, Guerin process, Marform process and the hydraulic deep drawing process to name a few.

The Marform process, for example, operates using the principle of rubber pad forming techniques. Deep-recessed parts with either vertical or slopped walls can be formed. In this type of forming, the die rig employs a rubber pad as one tool half and a solid tool half, similar to the die in a conventional die set, to form a component into its final shape. Dies are made of cast light alloys and the rubber pad is 1.5-2 times thicker than the component to be formed. For Marforming, single-action presses are equipped with die cushions and blank holders. The blank is held against the rubber pad by a blank holder, through which a punch is acting as in conventional deep drawing. It is a double-acting apparatus: at first the ram slides down, then the blank holder moves: this feature allows it to perform deep drawings (30-40% transverse dimension) with no wrinkles.

Industrial uses of deep drawing processes include automotive body and structural parts, aircraft components, utensils and white goods. Complex parts are normally formed using progressive dies in a single forming press or by using a press line. (Some parts are Cups, Pans, Cylinders, Domes and Hemispheres Irregular Shaped Products)

Workpiece Materials and Power Requirements
Softer materials are much easier to deform and therefore require less force to draw. The following is a table demonstrating the draw force to percent reduction of commonly used materials.

Drawing Force Required for Various Materials and Reductions [kN]

MORE IMAGES


	· Copper - Formed Fittings

	· Copper - Stamped Caps

	· Frame Corner - New and Old Stamped Brass Part

	· Frame Corne - New & Old Part Stamped in Brass

	· Frame Corner - Stamped Part to Match Brass Extrusion

	· Gauge Pointers - Stamped and Painted

	· Lock Parts

	· Medical Bracelets - Stainless

	· Medical Dog Tags - Stainless and Painted

	· Simple Stamping Plate

	· Stamped Hook

	· Stamped Hooked Assembly

	· Stamped Part - Assembled

	· Stamped Parts - Plated

	· Stamped Plates

	· Stampings - Electronic Parts

	· Washer - Brass (Non Standard)

	· Wire Formed Part - Coated

DOWNLOADS


		Conversions of Fraction to Decimal (PDF, 36KB)

		Hardness Conversion Table (PDF, 55KB)

		Metal Weight Conversion Table (PDF, 29KB)

		Wire Gauge Chart (PDF, 33KB)

		Common Metric Equivalents (PDF, 39KB)

Custom Metal Stampings & Wire Preforms

Tooling Capabilities

Workable Metals

Press Tonnage

Tolerance

Value-Added Services

Order Quantity

Typical Lead Time

Standards

Quality Assurance