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Should I laser cut or stamp flat sheet metal parts?
Laser cut flat parts until volume reaches a few thousand a year: there is no tooling, and each part costs laser time by cut length and pierce count. Past that, a short-run or compound blanking die, typically $1,500–$15,000, often pays back within the first one or two orders of 2,000 or more parts, and pierced features hold ±0.002–0.005 in (±0.05–0.13 mm).
Which is cheaper at your quantity?
The same bracket, each process in a suitable material (1008 CRS and 1008 CRS).
| Quantity | Stamping | Sheet metal |
|---|---|---|
| 10 | $672 | $15.70 |
| 50 | $134 | $6.12 |
| 100 | $67.20 | $4.92 |
| 500 | $13.80 | $3.96 |
| 1,000 | $7.23 | $3.84 |
| 5,000 | $6.98 | $3.74 |
| 10,000 | $3.66 | $3.73 |
| 50,000 | $0.99 | $3.72 |
| 100,000 | $0.66 | $3.72 |
Where each pays off
Metal stamping
1101001k10k100k1M+
- Tooling
- 3–12 weeks
- First article
- 1–2 weeks after die tryout
- Production
- 2–4 weeks per release
±0.002–0.005 in (±0.05–0.13 mm) on pierced features; ±0.010 in (±0.25 mm) across bends
Sheet metal fabrication
1101001k10k100k1M+
- First article
- 1–2 weeks
- Production
- 2–4 weeks per release, including finishing
±0.004–0.005 in (±0.10–0.13 mm) laser or punch
Which should you pick?
Pick Stamping when
- Repeat orders run a few thousand parts or more
- Small parts have so many holes that pierce time dominates
- Holes need ±0.002 in (±0.05 mm) relative to each other
- Forms, tabs or embosses can be added in the same die
Pick Sheet metal when
- Volume is under a few thousand parts a year
- Revisions are frequent
- Blanks are large, up to full 60 × 120 in (1.5 × 3.0 m) sheets
- Many part numbers can be nested on one sheet
Key differences
| Stamping | Sheet metal | |
|---|---|---|
| Edge condition | Sheared edge with burr up to about 10% of thickness; call out the burr side | No burr roll; thin heat-affected zone, with oxide on steel cut with oxygen assist |
| Minimum hole diameter | 1× thickness in mild steel; 1.5–2× in stainless | About 1× thickness |
| Tooling | $1,500–$15,000 short-run or compound die | None |
| Time per part | One press stroke | Scales with cut length and pierce count |
| Cost of a revision | Die rework | Revise the cut file |
| Material layout | Strip layout fixed by the die | Nests many part numbers on one sheet |
Questions
What quantity justifies a blanking die?
Often a few thousand parts a year. Laser cutting carries no tooling cost but more machine time per part. A short-run die often pays back within the first one or two orders at 2,000 or more parts, sooner for small parts with many holes.
How accurate is laser cutting?
Laser-cut features typically hold ±0.005 in (±0.13 mm), which suits most brackets and panels. Holes pierced in the same stamping station hold about ±0.002 in (±0.05 mm) when position matters more.
What is a compound die?
A compound die cuts a part's outline and pierces its holes in one press stroke. Parts come out flat, with holes held closely to the edge, which makes it a common short-run choice for washers, shims and flat brackets.
Try both on your part.
The builder prices the same geometry in every suitable process and material, with DFM for each.