High Volume Stamping

High Volume Metal Stamping for Continuous, Large-Scale Production

Wisconsin Metal Parts provides high volume metal stamping services designed for production programs exceeding 1 million parts annually. These projects require careful coordination of tooling, material flow, inspection, and maintenance to ensure uninterrupted output and consistent part quality.

Our team develops comprehensive production strategies that support long-running stamping programs, balancing tooling durability, throughput, and quality control to meet demanding production requirements.

Tooling for High Volume Stamping

Tooling plays a critical role in the success of high volume metal stamping programs. Tool design is driven by part complexity, tolerance requirements, and expected production volumes.

For high-volume applications, we utilize “Class A” progressive stamping dies, which are built with advanced components designed for longevity and serviceability.

Key tooling features may include:

• Guided strippers with ball bearing guide posts
• Replaceable cutting and forming inserts
• Modular tooling components for maintenance and replacement
• Multi-part output designs when geometry allows

Carbide cutting inserts are often used to extend tool life and increase output between maintenance intervals. These components must be processed carefully to avoid damage to material binders, which can lead to premature failure. Our in-house toolroom is equipped to make and repair these components on-site.

Specialized coatings may also be applied to cutting and forming surfaces to further extend tool life and reduce wear.

Preventive Maintenance & Tool Longevity

A well-designed tool must be supported by a structured preventive maintenance program to ensure continuous production.

Best practices for high volume stamping include:

• Maintaining spare tooling components and wear items
• Using sharpening shims and replaceable inserts
• Tracking maintenance intervals through detailed logs
• Monitoring tool condition through inspection data
• Proper tool storage to avoid environmental damage

A disciplined maintenance program minimizes downtime and ensures consistent part quality throughout long production runs.

Quality & Inspection for High Volume Production

High volume stamping programs often require enhanced quality controls and traceability. Initial setup and in-process inspection plans are increasingly common as well to ensure quality of the die build.

Inspection plans are typically defined by customer requirements and may include:

• First Article Inspection Reports (FAIR)
• PPAP documentation
• CPK data collection
• Lot control tracking throughout production

Lot traceability can be maintained from raw material through all secondary operations, including subcontracted processes, with retention of inspection samples when required. A strong quality system ensures that any potential risks for non-conforming parts are identified and addressed early in the production process. As an ISO 9001:2015 certified and ITAR registered manufacturer, we maintain strict quality and security standards and comply with NIST SP800-171.

Supporting High Volume Manufacturing

Successful high volume stamping programs depend on aligning multiple factors:

• Tooling design and durability
• Preventive maintenance planning
• Quality control systems
• Production scheduling and capacity

At Wisconsin Metal Parts, we integrate these elements to support long-term, high-output manufacturing programs, ensuring reliable production and consistent part performance.