The Benefits of Leveraging Laser Cutting Services Over Traditional Blank Dies
Traditional methods, like progressive dies, have long been the standard in the manufacturing industry, especially when producing higher volumes. However, advancements in laser cutting technology have caused our team to reevaluate our processes. At PMMCO, we’ve discovered that laser cutting often outperforms progressive die stamping, offering a flexible, cost-effective, and efficient solution for many applications.
Here’s how our laser cutting services have improved PMMCO’s custom fabrication process and why this cutting-edge solution could be the best fit for your next precision sheet metal project.
The Drawbacks of Traditional Stamping Methods
Progressive die stamping has long been the standard for high-volume production—approximately 10,000 to 50,000 parts annually. This method involves building an expensive die, setting up a coil, and running the die to produce components. However, it comes with significant drawbacks, including:
Large inventory requirements: Producing large quantities can lead to overstocking, which conflicts with our company’s Lean manufacturing initiatives.
High upfront costs: Creating a progressive die requires a substantial investment—especially investing in a press capable of handling large, heavy parts.
Wear and tear: Stamping thick or hard materials causes significant strain on both dies and presses, requiring frequent maintenance and the potential for increased downtime.
The Superior Alternative: Laser Cutting
Our laser cutting services eliminate many of these challenges and offer the following value-adds:
Flexibility and Cost Savings
Laser cutting eliminates the need for costly dies, allowing for quick adjustments to part designs. Modifying a laser cutting program involves updating software, whereas changes to a stamping die require time-consuming redesign and manufacturing. As a result, our team can be more flexible and agile when accounting for design modifications.
Perfect Edge Quality
Unlike stamping, which can yield rake or other imperfections on thicker parts, our laser cutting services produce straight, high-quality edges, even on thick materials. This precision ensures the final product meets stringent customer specifications without additional finishing steps.
Increased Efficiency
Advancements in laser technology have drastically improved cutting speed. For instance, nearly a decade ago, our team could cut 80 to 100 inches of quarter-inch thick material per minute. Today, we can achieve nearly 500 inches per minute! This speed enables the PMMCO team to produce more parts in less time, reducing lead times on higher-volume projects.
“Lean” Operations
Laser cutting supports smaller lot sizes, aligning with Lean manufacturing principles by minimizing inventory and waste. Customers can order precisely what they need when they need it without overcommitting to large production runs.
Combining Laser Cutting with Press Forming: Our Hybrid Approach
At PMMCO, we’ve found success with our hybrid solution. Instead of relying solely on blank dies or laser cutting, we use lasers to create the blanks and presses to handle the finish forming. This approach offers:
Precision tolerances: Laser-cut blanks (combined with press forming) achieve tight tolerances that meet customers' requirements.
Cost efficiency: By leveraging the strengths of both methods, we deliver high-quality parts at a fraction of the cost of traditional methods.
Partner with a Metal Fabricator Who Thinks Outside-the-Box
For higher-volume parts, laser cutting provides a clear alternative to traditional stamping, delivering:
Lower costs, as customers no longer need to invest in costly upfront tooling.
Greater flexibility. Lasers can make adjustments on the fly so that design changes can be reflected in production almost immediately instead of weeks down the line.
Top-notch quality and precision.
At PMMCO, we welcome the opportunity to approach projects from a different angle while tailoring solutions to our customers’ unique needs. Whether we’re leveraging lasers, presses, or a hybrid approach, our team is committed to helping our customers achieve their goals without being tied to a single manufacturing method.
If you’re seeking an innovative, cost-effective solution, request a quote from Progressive Metal Manufacturing Company to explore how our approach yields superior results.