Sheet metal die design converts finished-part geometry into a stable sequence of manufacturing operations. Engineering starts with material behaviour, press conditions and dimensional risk—not by machining steel directly from the drawing.
Manufacturing then turns the approved design into a working production tool through suitable steels, precision processes, assembly and measured press trials.
1. Technical data and manufacturability
The 3D model and drawing are compared to confirm grade, thickness, tolerances, burr direction, visible surfaces, joining points, volume and target press line.
Sharp corners, inadequate bend radii, inaccessible cuts and springback risk are identified before quotation and design release.
2. Process plan and strip layout
Engineers define the number and order of cutting and forming operations. Progressive projects require strip width, pitch, carrier and yield calculations; transfer projects require gripping and motion studies.
The target is a stable, maintainable process at production speed—not merely a geometrically possible sequence.
3. Detailed die engineering
Die sets, plates, punches, inserts, guides, strippers, springs, sensors and scrap channels are modelled. Cutting clearances follow material behaviour and wear parts are designed for replacement.
Design reviews cover interference, stroke, shut height, clamping, lifting safety and operator access.
4. Machining, heat treatment and assembly
CNC milling, wire and sinker EDM, grinding and heat treatment are planned around controlled datum surfaces. Components are assembled, clearances adjusted and dry-cycle checks completed before the press trial.
5. Press trial, measurement and launch
First-off parts are measured for burrs, marks, cracks, wrinkles, springback and geometric deviation. Evidence-based corrections and repeated trials continue until approval.
Launch success means producing the approved component safely, repeatedly and at target speed with documented maintenance points and critical spares.