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Stamped for Success
Smarter Stamping Strategies for Electrical Design Engineers
Issue 036
When designing stamped metal components for electrical applications, even small adjustments can make a big difference in cost, efficiency, and long-term reliability. Whether you’re working on busbars, terminals, or brackets, understanding material selection, in-die assembly, and stamping process optimizations can help you cut waste, speed up production, and improve performance.
Let’s dive into key design strategies that can save time and money while ensuring your stamped parts meet performance standards.
Choosing the Right Material: Performance vs. Cost vs. Longevity
Material selection in electrical stamping is like choosing the right engine for a performance vehicle—conductivity, strength, and cost all matter.
Here’s a breakdown of common materials for stamped electrical components:
✅ Copper – The gold standard for conductivity. Great for busbars and terminals, but expensive. Plating with tin, nickel, or silver helps prevent oxidation.
✅ Aluminum – A lower-cost, lightweight alternative, but it’s not a direct replacement for copper in all cases. Protective coatings (tin or nickel) are often required to prevent oxidation and ensure long-term reliability.
✅ Stainless Steel – High strength and corrosion resistance, but significantly lower conductivity. Best for brackets and structural components, not power distribution.
✅ Beryllium Copper & Phosphor Bronze – Excellent for high-precision connectors due to their spring-like properties and wear resistance.
💡 Pro Tip: If switching from copper to aluminum in busbar applications, ensure proper surface treatments to prevent oxidation and galvanic corrosion.
In-Die Assembly: When It Works (and When It Doesn't)
Instead of stamping a part, then assembling it separately, modern die technology allows multiple processes in one stroke—reducing labor and cycle time.
🔹 In-Die Tapping – Eliminates secondary machining for threaded holes.
🔹 In-Die Riveting & Contact Insertion – Automates terminal or connector placement for perfect alignment.
🔹 In-Die Bending & Forming – Reduces multiple press operations into one efficient process.
💡 Pro Tip: In-die assembly works best for high-volume production but may not be cost-effective for low-volume or highly complex designs due to longer setup times and increased die wear.
High-Speed Stamping: Designing for Faster, More Efficient Production
Stamped parts are often produced in the millions, so optimizing for speed and consistency is crucial.
⚡ Uniform Material Thickness – Ensures smooth feeding in high-speed presses.
⚡ Springback Compensation – Materials like stainless steel tend to “spring back” after forming. Adjust die clearances and use secondary forming techniques to maintain accuracy.
⚡ Nesting & Progressive Die Optimization – AI-driven nesting software can improve material usage and reduce scrap rates by optimizing blank layouts.
💡 Pro Tip: If your part requires tight tolerances at high speeds, consider progressive die stations with built-in stress relief operations to counteract material distortion.
Final Thoughts
Smart design decisions in stamped metal components can eliminate unnecessary costs and improve efficiency.
✔️ Select materials carefully based on conductivity, corrosion resistance, and cost
✔️ Use in-die assembly where it makes sense, but weigh costs for lower-volume runs
✔️ Optimize for high-speed stamping, accounting for springback and nesting efficiency
By applying these practical strategies, you’ll create stamped parts that are cost-effective, reliable, and built for long-term success.
Gromax Precision Die & Mfg., Inc. specializes in designing and manufacturing precision metal stamped parts and tooling, including progressive stamping dies and custom equipment. With an on-time delivery rate of 99.68% and a defect rate of just 0.066%, the company ensures exceptional reliability and quality.
Gromax is ISO 9001:2015 certified and ITAR registered, serving industries such as medical, defense, aerospace, industrial automation, and automotive with high-quality, innovative solutions.