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Should my sheet metal part be stamped or fabricated?
Fabricate with laser cutting and press brake forming for prototypes, low volumes and designs still changing: there is no tooling and first parts ship in 1–2 weeks. Move to stamping once annual volume passes roughly 5,000–10,000 parts and the design is stable: a $1,500–$15,000 short-run die, or a $15,000–$100,000+ progressive die, cuts piece price sharply.
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
- The design is stable at 5,000–10,000 or more parts a year
- Small parts have many holes, tabs and embosses
- Part-to-part consistency from a hard die matters
- Gauges run as thin as 0.005 in (0.13 mm)
Pick Sheet metal when
- You need prototypes through a few thousand parts a year
- The design is still changing
- Enclosures and panels run up to full sheet size
- The part is a welded frame or assembly with inserted hardware
Key differences
| Stamping | Sheet metal | |
|---|---|---|
| Tooling | Die $1,500–$100,000+; 3–12 weeks | None; standard press brake tools |
| Production rate | Progressive dies 30–200 strokes per minute | Laser time by cut length; one brake hit per bend |
| Thickness range | 0.005–0.250 in (0.13–6.4 mm) | 0.020–0.250 in (0.5–6.4 mm) |
| Tolerance | Pierced features ±0.002–0.005 in (±0.05–0.13 mm); across bends ±0.010 in (±0.25 mm) | Cut features ±0.004–0.005 in (±0.10–0.13 mm); per bend ±0.010–0.015 in (±0.25–0.38 mm), ±1° |
| Formed features | Embosses, lances, extruded holes and coined features in the die | Mostly cut, bent, welded and hardware-inserted |
| Minimum flange | 2.5× thickness plus bend radius | About 4× thickness |
| Part size | Up to about 24 in (610 mm) on typical presses | Sheets to 60 × 120 in (1.5 × 3.0 m); bends to about 10 ft (3 m) |
Questions
When should I switch from fabrication to stamping?
When annual volume passes roughly 5,000–10,000 parts and the design is stable. For simple parts, a short-run die can pay back within the first one or two orders of 2,000 or more parts.
Can the same drawing be fabricated and stamped?
Usually, with small changes. Stamping allows shorter flanges and adds formed features such as embosses, while fabrication needs flanges of about 4× thickness. Have the stamper review the drawing before die design.
How much does a stamping die cost?
Short-run and compound dies typically cost $1,500–$15,000. Progressive dies usually run $15,000–$100,000 or more, depending on station count, part size and material. Annual volume should decide the die type.
Try both on your part.
The builder prices the same geometry in every suitable process and material, with DFM for each.