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What are the benefits of using deep drawn metal stamping for car parts?

Seldom seen, always essential.

 

deep drawn auto parts

Types of Deep Drawn Automotive Components

Deep drawn automotive components can be found in several places in the cars we drive today. While you may not be able to see these parts, they are necessary when it comes to the operation of our cars. When you tune into your radio, deep drawn components are in the antenna system. When you steer your car, there are deep drawn components in the steering wheel and front end suspension components which allow you to turn and steer your vehicle with ease.

Prospect Machine Products has the capability to produce various auto components through the deep draw process including:

  • Engine control components for fuel efficiency consumption
  • Temperature regulation components
  • Sealing applications
  • Dashboards
  • Seating
  • Steering column areas
  • Frame and suspension assemblies
  • Antennas
  • Oxygen sensors
  • Power outlets

Benefits of Using Deep Draw Metal Stamping for Car Parts

The automotive industry is one of the largest markets to utilize deep drawn parts. There are several benefits for using deep draw metal stamping for car parts as it is an economical way to fabricate a range of various components in several sizes, shapes, complexity and precision.

One of the major advantages is that deep drawn auto parts are formed with a solid wall around the entire diameter. The benefit of a seamless construction is that components are leak-resistant, waterproof and airtight. 

Another advantage of using deep draw for car parts is the increased strength properties making parts more durable under harsh automotive conditions. During the deep drawing process strain hardening occurs. Strain hardening (also called cold-working or work-hardening) is the process of making metal harder and stronger through plastic deformation. The strength of the metal is increased, and ductility decreases.

Deep draw stamping is the quickest and most cost-effective method for high volume production runs. Deep draw transfer presses, such as the ones used at PMP, allow for greater flexibility for adding secondary operations into the machine helping to reduce the outside secondary operations and added costs.

Sheet metals ideal for the deep draw stamping for car parts include aluminum, brass, cold rolled steel, copper and stainless steel.

The Process for Deep Drawn Auto Parts

The deep drawn stamping process is a practice of forming a flat piece of sheet metal into a die to make precise, round and shaped components. This is achieved by feeding a coil of flat metal into a press with stations of tooling, each performing repeated operations on the metal until the final shape is complete.

The first station cuts a blank from a strip of sheet metal. The blank is a flat circular piece of metal that will eventually turn into a finished part. The blank is then pushed into a die by a punch forming a cup shape and through subsequent stations, will be drawn out to length. After drawing the metal to length, the remaining stations will add any additional required features and trim off any excess material. With automated transfer presses moving each part from station to station, the deep draw process is very efficient, and by using the detached blank from the coil of raw material to travel through stations of the transfer press, raw material scrap is greatly reduced. 

Furthermore, the process for deep drawn auto parts can be broken down into the following steps:

  • Design review through 3D CAD
  • Press selection
  • In-house tool build
  • Equipment setup
  • Sampling/PPAP
  • Final production

Want to discuss a design or project?

Our deep draw metal stamping experts at Prospect Machine understand the importance of effectively producing automotive components required to complete the assembly of a vehicle.

Contact our Deep Draw Specialists at PMP to book a meeting or get a quote today

What is Tooling?

punches, dies and fingers needed for deep drawn process.

What is tooling? 

If you look up the word tooling in a dictionary you will likely find a definition along the lines of “The planning, making and arrangement of tools for a particular manufacturing process.” 

Tooling is the task of developing and engineering the products or “tools” and equipment required to produce and manufacture a part or assembly. Think of a cupcake. Without a cupcake pan you would not be able to continuously reproduce the same shape. 

There are many different types of tooling but what is tooling in manufacturing? Tooling used in manufacturing, also known as machine tooling, is an important part of the manufacturing process. When a unique piece of equipment coupled with unique tooling is needed to carry out a manufacturing operation, it would be considered “tooled.” 

Why is tooling important?

Tooling is a critical part of the manufacturing process since the precision and characteristics of the tooling define the quality of the finished goods. More importantly, properly designed tooling allows for a product to function properly, repeat results, reduce man hours, etc. As a skilled tooling manufacturer, PMP is able to deliver well-designed and well-made tooling specific to the deep draw metal forming process. This allows for manufacturing processes to be quicker and more cost-effective. Proper tooling also improves reliability, repeatability and reduces time related to repairs and maintenance.

Final parts always need to be within a specific tolerance to function properly. If the tooling is not made properly, the final part can be unsuccessful and may end up with faults indicating that they can break or degrade quickly. Tooling failure can lead to production delays, lost time or even part rejection.

A successful tooling process starts with designing tools to best meet critical features and functions of the part. We build tools in-house which allows us to control quality and tool delivery lead times. Next, our tool makers set in and adjust tools as needed to produce first piece samples for customer approval. The tooling process can range in cost due to many variables such as the number of operations to complete the part, part complexity and required tolerances. The tooling charges at PMP encompass the tool design for the part, building the machine tools and all activities to produce PPAP or first piece samples for customer approval. Here at PMP, the tooling charge is a one time charge and covers the design life of the current part revision.

Why Use Tooling for Metal Forming? 

Tooling plays a vital role in the metal forming process and the mode in which the deep drawn process takes place.

The tooling process helps deliver an efficient production process which allows manufacturers to provide high-quality and customized products while still retaining affordable production costs.

The tooling process for the manufacture of deep drawn metal forming requires engineering and niche design principles not used in other forms of manufacturing. The combined experience of our design and tool building teams ensure proper selection of tooling materials that guarantee longevity while maintaining customer required tolerances and minimal variation between runs. The deep draw process uses hardened tooling materials, such as steel,  which can withstand multiple production cycles allowing the deep draw manufacturer to produce high volumes of parts. Soft tooling would not be an optimal choice for deep draw metal forming as it only allows manufacturers to produce samples and prototypes and lacks the durability or wear resistance for high volume production. 

Think about that cupcake pan again; you are using a “tool” to make many cupcakes for years to come! 

Want to discuss a design or project?

Do you have a deep draw metal stamping project that would be best handled by a provider that truly understands the customer experience and is committed to your success?

Contact us and schedule a meeting with our Tooling Specialists at PMP today!

Email info@pmpdeepdraw.com or call 203-758-4448

Karen McWhirt, President of PMP Chats with Ari Santiago in Made in America Podcast

Karen McWhirt, President of Prospect Machine Products, a deep draw manufacturer, chats with Ari Santiago in this week’s Made in America podcast episode!

Karen McWhirt, President of Prospect Machine Products, a deep draw manuacturer chats with Ari Santiago in Made in America Podcast

October is manufacturing month and what a great way to celebrate! Manufacturing month honors modern manufacturing and is meant to encourage the next generation of manufacturers.

I had the opportunity to tag along with Karen to sit in on the recording of the Podcast. It was such a fun and engaging experience and I was surprised to learn upon our arrival that there was no editing!

Karen McWhirt, President of PMP, a deep draw manufacturer

Karen and Ari touch upon many pertinent topics in today’s manufacturing industry including:

    • Women’s everchanging roles in manufacturing and the strengths they can bring into the deep draw stamping environment
    • Working with CONNSTEP (Our statewide MEP) and SMA (Smaller Manufacturers Association of Connecticut) and the beneficial services that they provide such as networking, training, and support of small manufacturers in Connecticut
    • 5s and how it has positively impacted our business in the deep draw metal stamping industry
    • How people, technologies, and processes are the keys that we need focus on for our future success and to continue to be relevant as a deep draw metal stamping manufacturer
    • How the latest information technologies in sales and marketing have brought us deep draw stamping business and as Ari mentions,” lean into the changes and not to be afraid of them if you want to continue compete.”

Tune in and learn more by watching the full episode here!

Podcast website: http://madeinamericawithari.com/

YouTube page: https://www.youtube.com/user/itdirect151

Apple podcast link: https://tinyurl.com/y3olg8e3  

Have a deep draw metal stamping project that would be best handled by a provider that truly understands the customer experience and is committed to your success? Contact us! Email info@pmpdeepdraw.com or call 203-758-4448, X25 for our Sales Manager, Nicole Spaeth.

By Nicole Spaeth, Sales Manager at Prospect Machine Products

What We Do And Why We Do It

Deep Drawn Metal StampingsWhat we do:

We are a contract manufacturer of deep draw metal stampings. Deep draw stamping is a process in which the work piece is gradually stretched and formed into its final shape through a transfer press operation. Each operation within the press or “station” is a calculation of ratio between the force required to achieve the maximum depth of the work piece without deforming the metal. On average, most of our deep drawn parts pass through eight to twelve stations of operation to become the finished component. Visually, if you had a selection of deep draw shapes within your hand, they would resemble tubes, cans, covers or caps. Consumer products with deep draw components include household batteries, caps for perfume and cologne bottles, and some costume jewelry shapes.

Deep Draw Sealing ComponentsWhy we do it:

Our founder was a deep draw tool and die maker. Deep draw tool making is highly specialized within the tool and die industry, requiring a lengthy apprenticeship and close mentoring, beginning at the age of sixteen in vocational high school and work study pre-apprenticeship. This kind of training and its commensurate awards has created a great deal of trust, loyalty, and longevity for our business.

We do it because our parts are essential within our customers’ supply chains. Without our components, they could not complete their products. Whether it is an appliance part, a bearing part, an automotive part, a valve pump part, or a medical device part, our customers rely on us for its supply.

Finally, we do this to make life better for all of us. Our deep drawn components are in pollution control assemblies, fuel efficiency assemblies, drug and food processing equipment, and critical medical device delivery systems.

Have a deep draw metal stamping project that would be best handled by a provider that truly understands the customer experience and is committed to your success? Contact us! Email info@pmpdeepdraw.com or call 203-758-4448, X25 for our Sales Manager, Nicole Spaeth.

COVID-19: A Wake-Up Call for American Industry and Its Supply Chain

 

Deep Drawn Metal Stamping-Prospect Machine Products Made in the USA

 

 

 

 

 

 

COVID-19: A Wake-Up Call for American Industry and Its Supply Chain

By Anthony Romero

Sales and Applications Engineering Manager – Prospect Machine Products

 

As stated by Brig. Gen. John Adams (U.S. Army, retired), president of Guardian Six LLC, in an article for IndustryWeek:

“The COVID-19 pandemic is the straw that broke the camel’s back. From ventilators and personal protective equipment to medicines, we’ve come to learn that China controls the production and distribution of these essential items. Large swaths of our economy are left without an industrial base to ramp up in times of crisis, even when doing so is a matter of life and death. Scrambling to have auto manufacturers produce ventilators during a pandemic has certainly clarified the crisis.”

In manufacturing, the return to the U.S. of production being done offshore (called “reshoring”) was a strong trend even before the coronavirus pandemic. However, its importance and criticality has been even more evident in the last few months.

When it comes to deep draw metal stamping , there are several advantages to having a U.S.-based contract manufacturer servicing the American continent (especially North and South America). Some of these benefits include:

  • Proximity. Less geographic distance between the design center and the contract manufacturer facilitates face-to-face communication and the development of a strong customer/supplier relationship. Although there are several modern communication tools like video chat, screen sharing, local toll-free numbers, and customers setting up their own virtual meetings knowing the supplier’s schedule (self-service meeting scheduling) that assist with communication, there is no mode of interaction that is better than physical meetings. When people sit down together, body language, tone of voice, facial expression and other factors play an important role in developing trust between buyers and salespeople as well as between designers and manufacturing engineers.
  • Trade agreements. The USMCA and similar trade agreements improve the commercialization of products and services offered by U.S. contract manufacturers. Prospect Machine Products has numerous customers in Mexico, where such agreements are beneficial.
  • Language. Although the primary language in technical and business discussions is English, it just so happens that many U.S. contract manufacturers have bilingual personnel, allowing dialogues to be conducted in the native language of the Latin American customer (often Spanish or Portuguese).
  • Transportation. The relatively small distance between U.S. contract manufacturers and assembly centers in North and South America results in lower transportation costs compared to those to and from Asia.
  • Contingency plans. Most U.S. contract manufacturers are ISO:9001 2015 certified, so they are required to have contingency plans in place enabling them to react quickly to disruptive events.
  • Response to market volatility. Customer service personnel at U.S. companies communicate frequently with customer production planning departments, enabling a rapid response in the event of market volatility.
  • On-site technical training: Seminars and technical assistance can be provided at the customer site explaining the deep draw metal stamping process, raw materials, quality in deep drawn components, and other subjects. As an example, Prospect Machine Products provided a recent “Lunch and Learn” session in San Miguel de Allende – Mexico at a large OEM that supplies components to the American automotive industry. See previous blog 

All these benefits are enjoyed when doing business with Prospect Machine Products —a Connecticut, USA-based company.

Have a deep draw metal stamping project  where the timeliness, quality, and affordability of components is critical? We’re happy to talk with you about how Prospect Machine Products can deliver the parts you need and the value you want. Contact us!

Email info@pmpdeepdraw.com or call 203-758-4448, X25 for our Sales Manager, Nicole Spaeth.