progressive die manufacturing

Product Advantage

This progressive mold is manufactured for producing industrial steel brackets. Besides that, it can also help in stamping processes like cutting, bending, and coining. The regulated alignment systems guarantee the correct positioning of the parts throughout all the stations. With this solution, it's possible to work with more massive and heavier presses and it is thus appropriate for the more demanding machinery and all sorts of structural hardware.

Maximizing Production Efficiency

Progressive molds gain superior efficiency by performing a number of operations in one go - for example, punching, bending, and cutting. It is this fast-track process that not only reduces cycle times to a great degree and thus improves the output of completed products, but it is also very suitable for mass production. The progressive molds carry the material automatically through a series of stations; it is thus not necessary that we move the material manually or use a secondary tool. This leads to more productivity and also product standardization. The combination with automatic feeders and precise alignment minimizes the amount of the rejected material and supports the concept of the lean manufacturer. The tool is ideally suited to high volume, repeatable production with customers enjoying the luxury of time-saving benefits and reduced labor costs.

Precision and Consistency with Progressive Mold Technology

The ability of a progressive mold to consistently produce components with complex geometry and also have the part dimensions maintained without variation is one of its major characteristics. The mold is built up of several stages, which are all made according to designer's project and machined with the highest precision to assure the same tight tolerance for thousands and even millions of parts. The strip feeding system keeps the parts in sync and placed in the same position repeatedly all the way through the process. The tools are made of high-quality materials and can be provided with finishing treatments like nitride or PVD coatings, thereby making the die life cycle and production precision even longer and more accurate, respectively. In these areas e.g., automotive, electronics, and medical, where the precision is everything, such reliability is a sine qua non.

Cost Savings through Material and Labor Efficiency

The use of progressive molds stands as the most essential factor for the company in terms of overall production cost reduction. The basic form of this mold is such that it is developed to use every meter of the material to the full, thus less scrap is to be generated. Moreover, the process of the tool is automatically completed, so you have to operate it by hand which results in the optimization of the labor costs and the elimination of mistakes caused by people. Secondly, there are no various machines or set-ups required in the process as all the functions are performed in a single tool. Besides the cost per part is reduced, thus there is an increase in the output of progressive molds making the companies' choice of achieving maximum profitability without losing quality a wise one in the long run.

Long Service Life and Low Maintenance

Long and reliable services are what these progressive molds are built for if they are regularly maintained. The molds are manufactured with high-quality steels, including SKD11, D2, and tungsten carbide, which tolerate various mechanical pressure ranges over a long time. Along with heat treatment and surface coating, the aforementioned make prolongation of the mold's lifespan virtually an easy matter. Thanks to being modular in design, the tools can be put into pieces interchangeably with each other without removing them, hence making the whole work less costly and having no downtime. Up to a few million cycles, as long as a progressive mold is well-kept, it can be applied without unnecessary causation of the weakness and maintain its standard efficiency, thus eliminating the need for the repair.

Progressive Mold for Medical Stainless Steel Instruments

The innovative mold, made specifically for surgical and diagnostic instruments of stainless steel, is a perfect fit for the most demanding hygiene requirements and allows the production of components with high accuracy. At every station, crucial operations like bending, piercing, notching, and deburring that have to be performed are made in an uninterruptedly progressive action. The mold, created by cold hardening H13 tool steel of high hardness level, is very robust. As it is quick and comes with hygienic mold plates that are easy to clean, it can be used in cleanroom or sterile production conditions, and it is equipped with quick-release plates for easy sterilization. By virtue of its narrow die clearance and the bright cleaned surface, it prohibited the bad things—that are, the medium from which the contamination spreads, and the adhesive surface causing the material to stick from happening. The tool is of a type which lends itself to be used for the pressing of parts, the example of components that can be given are the arms for forceps, locks for instruments, and the arms of knives, which means the medical OEMs have the advantage of achieving the highest possible productivity and the minimum amount of waste. It includes the ability to detect out-of-specification parts before they are fed down the line using sensors, which are an essential feature. The press that is used with the mold has a speed that is as high as 200 SPM and maintains the precise dimensions. The mold represents a high-frequency production tooling solution used to make precision parts made of stainless steel that are required in large quantities.

progressive die manufacturing

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