Common Errors in Metal Stamping Part Design (and How to Avoid Them)
- ester1302
- 6 days ago
- 3 min read
Introduction
More than 70% of cost overruns in metal stamping originate in the design phase. An excessively tight bending radius, an unnecessarily strict tolerance, or poorly selected material can turn a profitable project into a constant source of problems.
At TYRSA, with over 50 years of experience in tooling and metal stamping, we've seen how small changes in the initial design can save thousands of euros and weeks of delays. The secret? Applying Design for Manufacturing (DFM) criteria from the very first sketch.
Let's analyze the 7 most common errors and how to avoid them.
1. Ignoring the Stamping Process in Design
The problem: Designing while thinking only about the final function, without considering how the part will be manufactured.
Consequences:
Bending radii that are too small, causing cracking
Geometries impossible to form
Unplanned additional operations
How to avoid it:
Apply the basic rule: minimum radius = material thickness
Review the design with the manufacturer before building the die
Always ask: "How will this come out of the die?"
2. Inadequate Material or Thickness Selection
The problem: Choosing material based solely on theoretical criteria, without considering its formability.
Consequences:
Greater forming effort and die wear
Dimensional stability problems
Unnecessarily high cost per part
How to avoid it:
Select considering: function + process + production series
Consult the material's deep drawing characteristics
Don't oversize thickness if not necessary
Key data: Replacing structural steel with deep drawing steel can reduce forming effort by 30%.
3. Overly Strict Tolerances
The problem: Defining tolerances of ±0.05 mm across the entire part when only one or two dimensions are critical.
Consequences:
Die cost increase up to 40%
Reduced production speed
Higher rejection rate
How to avoid it:
Apply functional tolerances: only tighten where necessary
Differentiate critical zones (assemblies) from free zones
Follow standards like ISO 2768 for general tolerances
Practical rule: If a dimension doesn't affect assembly or function, use general tolerance.
4. Forgetting Part Ejection
The problem: A perfect design on paper that sticks to the die or deforms when ejected.
Consequences:
Sticking due to vacuum effect
Elastic deformation during extraction
High cycle times
How to avoid it:
Plan for slight tapers (1-3°) to facilitate extraction
Avoid deep concavities without exit
Consult about the most suitable ejection system
5. Overly Complex Designs for a Single Operation
The problem: Concentrating too many shapes and bends in a single press stroke.
Consequences:
Excessively complex and costly dies
Greater risk of breakdowns and stoppages
Difficulties maintaining tolerances
How to avoid it:
Divide the process into progressive operations
Simplify geometry without compromising function
Consider secondary operations outside the die
Shop floor reality: A small design change can reduce die cost by 20-30%.
6. Not Thinking About Die Life
The problem: Designing edges that are too thin or critical sections that stress the die.
Consequences:
Premature punch wear
Constant adjustments to maintain tolerances
Production stoppages for repairs
How to avoid it:
Design with adequate margins for punches
Avoid sharp corners that concentrate stress
Think in terms of hundreds of thousands of hits, not just the first part
7. Lack of Design-Manufacturing Collaboration
The most important of all. Most errors stem from lack of communication between designer and manufacturer.
When the manufacturer participates from the beginning:
Problems are detected before making the die
Alternatives that reduce costs are proposed
Later modifications are minimized
At TYRSA we work from the initial phase with our clients, applying our experience to ensure the design is manufacturable, efficient, and competitive.
Key data: Projects with prior DFM review reduce time to production by 40%.
Conclusion: How to avoid Common Errors in Metal Stamping Part Design
Good metal stamping design goes beyond the final shape. Considering the process, material, functional tolerances, and die life is key to achieving efficient and competitive parts.
At TYRSA we know that the best investment is reviewing the design before going into production.
Do you have a metal stamping project?
Our technical team can review your design and propose improvements that optimize cost, quality, and time.
Contact us:
📧 comercial@tyrsa.com | 📞 (+34) 93 460 98 00 | 🌐 www.tyrsa.es
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