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One of our most common product niches at Stamped Products Incorporated is metal stamped parts, panels, and related components for consumer appliances. Located in Gadsden, Alabama and backed by more than 60 years of mass production experience, we offer appliance sellers a simplified supply chain combined with superior American manufacturing quality.

How Mechanical Stamping Providing Single-Source Manufacturing Solutions for Consumer Appliances

Sheet Metal Stamping and Fabrication

SPI processes and produces the custom sheet metal panels and components required for virtually any appliance project. We offer versatile metal stamping and welding services to create various components such as enclosures, casings, chassis parts, frames, brackets, and structural pieces.

Mass Production and Cost Efficiency

Our metal stamping services are highly flexible, capable of lower-volume appliance projects as well as high-volume production. Consumer appliance manufacturers often require large quantities of components, and therefore turn to overseas providers. Combined with the cost advantages of local manufacturing, our efficient stamping processes can achieve economies of scale while keeping production onshore.

Responsiveness and Flexibility

Appliances come in many shapes, sizes and materials, and volume requirements often fluctuate substantially. Tackling production entirely in-house, SPI offers the responsiveness and quick turnaround required to remain ahead of the market. Furthermore, as a customer-focused local operation, we offer far more collaboration and design flexibility than many of our overseas competitors. Our single-source capabilities enable the customization of components to meet your specific appliance requirements, optimizing costs while improving your products in the process.

More Than 60 Years of Superior American Metal Stamping Services

SPI has delivered quality American metal stamping solutions since 1962. Specializing in the manufacturing of consumer appliance parts and panels, our 124,000 sq.-ft facility offers the production capacity and responsiveness to both simplify and strengthen your supply chain.

Mechanical presses are preferred in many of today’s metal stamping applications for the production speed and simplicity the machines offer.

Compared to hydraulic presses, conventional mechanical stamping presses are easier to set up and operate, easier to maintain, while also offering a generally higher stroke speed to accommodate high-volume manufacturing requirements.

While hydraulic presses can offer a bit more versatility, mechanical presses are often the ideal choice for producing custom stamped parts that are complex but do not have very deep draws. From automotive parts and panels to HVAC and appliance stampings, mechanical presses are efficiently utilized across many industries and commercial applications.

At SPI, our metal stamping services utilize a wide range of highly capable mechanical presses, including transfer presses and progressive metal stamping systems. In this article, we break down the basic anatomy of the mechanical press, as well as some of its advantages the configuration offers over its hydraulic and servo-driven counterparts.

How Mechanical Stamping Presses Work – Put Simply Suppliers:

To illustrate the concept simply: mechanical presses use an electric motor to generate kinetic energy, which is stored in a massive mechanical flywheel.

For visualization purposes, it’s not dissimilar to the way a typical car engine generates torque at its crankshaft flywheel – except in that case power is generated from pistons above undergoing the combustion process. With a mechanical press, that energy is fed into the system externally, and the flywheel  in turn drives the connected punch-press system.

The Basic Anatomy of a Mechanical Stamping Press:

• Frame – The press is built on a sturdy frame that provides structural support and stability.
• Bed – The bed is a flat surface where the metal workpiece rests during the stamping process. It typically includes a die cushion or bolster plate to support the die.
• Die – The die is a specialized tool consisting of upper and lower sections. It is designed to shape and cut the metal workpiece into the desired form. The die is mounted onto the press, with the upper section attached to the ram and the lower section fixed to the bed.
• Ram – The ram is the moving part of the press that applies the necessary force to the metal workpiece. It is driven by a mechanical mechanism such as a crankshaft or eccentric gear. The ram moves up and down in a vertical motion.
• Clutch and Brake – The clutch and brake system control the movement of the ram. When engaged, the clutch connects the ram to the drive mechanism, allowing it to move. The brake system provides stopping power to halt the movement of the ram.
• Drive Mechanism – The drive mechanism converts rotary motion into linear motion to drive the ram. It is typically powered by an electric motor and consists of components like flywheels, gears, and crankshafts.
• Feed System – The feed system supplies coil stock or blanks to the stamping area, positioning them accurately for each cycle. It may involve rollers, grippers, or other mechanisms to advance the material.
• Control System – Modern presses use digital control systems to safely and accurately regulate various aspects of the stamping press. The stroke speed, timing, and force applied during operation are all precisely monitored and controlled.

The Basic Operation of a Mechanical Stamping Press:

When a stamping operation begins, the press operator feeds a metal workpiece into the press and positions it correctly. The control system initiates the stamping cycle, activating the drive mechanism. The ram descends under pressure, pushing the upper die section into contact with the workpiece. This force cuts and shapes the metal according to the design of the die.

After completing the stamping process, the feed system then advances the coil or blank into position for the subsequent cycle. This process continues in a continuous motion until the work order is complete.

Want to see what a mechanical press in action looks like? Check out SPI’s Gallery for a selection of our custom stamped parts and press equipment.

60+ Years of Quality American Metal Stamping Services

SPI has provided our customers with quality metal stamping services since 1962. Proudly based out of Gadsden, Alabama, our 124,000 sq.-ft facility has grown into one of the nation’s leading sources of custom U.S.A.-made metal stampings and weldments. Our company is a leading provider for Tier 1 and Tier 2 automotive stampings, as well as utility vehicle (UTV) and all-terrain vehicle (ATV) parts, HVAC components, consumer appliances, and agricultural equipment

Tier 1 and Tier 2 suppliers are two distinct categories of manufacturers in the automotive industry. The primary difference is that Tier 1 suppliers manufacture parts and components directly in contract with OEM automotive companies – i.e. the companies that actually design and sell vehicles, such as Ford, General Motors, and Fiat Chrysler.

Tier 2 suppliers, on the other hand, are contract manufacturers that produce parts for Tier 1 suppliers. These are sometimes fully completed car parts or, more often, individual components (such as custom weldments metal stampings) which the Tier 1 supplier then further fabricates and/or assembles.

In other words, the essential difference between Tier 1 and Tier 2 automotive metal stamping companies is how closely they work, collaborate, and contract with OEM car companies.

An Overview of Tier 1 vs. Tier 2 Automotive Suppliers:

Tier 1 Automotive Manufacturers

At the top of the automotive manufacturing are Tier 1 suppliers – contract manufacturers who generally only work with one or a few OEMs. These vendors keep a close relationship with the OEMs, taking on some design responsibility for the products. Tier 1 manufacturers are responsible for producing large, major parts and/or more complex multi-component assemblies.

Tier 2 Automotive Manufacturers

Tier 2 vendors produce the parts and subcomponents used by Tier 1 providers. These contract manufacturers often work on a build-to-print basis with little or no design responsibility. Common products are smaller metal stampings and weldments known as “child parts” which go into larger automotive assembly. 

A Brief Guide to the Overall Automotive Industry Supply Chain:

The companies that design, assemble, market, and sell automobiles – your common everyday “car companies” such as Honda, Toyota, and Volkswagen. OEMs handle the design of the overall vehicle, the branding, as well as the scope of the project. A product, once completed and distributed by the OEM, is associated with the OEM company.

The top level of automotive part manufacturers that work directly with OEM companies. Tier 1 suppliers produce their own parts but also partner with Tier 2 providers for various contract manufacturing services such as metal stamping and production welding.

Alabama’s Leading Tier 2 Automotive Manufacturer

Founded in 1962, SPI is backed by a long history of delivering quality metal stamping and welding services to the domestic automotive industry. We specialize in the manufacturing of:

• Chassis related components
• Seating brackets and components
• Airbag system components
• “Body in white” components

Based in Gadsden, AL, we offer superior quality and a simplified supply chain to automotive providers throughout the nation.

Complex welded assemblies are unique products made from multiple components, which are pieced together and precisely welded to create a complete assembly.

The ability to join separate components and materials into a fully finished assembly allows for more freedom and flexibility in the design process. For example, tubular components can be connected to forged structural members, or stamped metal parts can be integrated into  weldments to create turnkey products which are fully ready for use or installation.

Flexible Manufacturing Services for Custom Welded Assemblies

Complex welded assemblies come in many shapes, sizes, specifications, and functionalities. These products are commonly manufactured for a variety of different commercial and industrial applications including the automotive sector, agricultural equipment, HVAC components, and consumer appliances, to name a few.

Today’s customers throughout these industries increasingly demand the efficiency of lean manufacturing to remain cost-competitive and to simplify their supply chains. Welded assemblies achieve these goals by streamlining the production of highly complex products which would otherwise require multiple manufacturers and numerous post-production assembly processes.

Combining Multiple Materials and Components

The separate components that make up a complex welded assembly can be made from any variety of materials. Typically, structural components are metals such as steel and aluminum so that they can be welded with high-strength joints. However, plastics, rubbers, and composites can be integrated into the finished assembly as well.

Robotic Welded Assemblies

The actual assembly process requires the use of various specialized welding techniques which are optimized for the required materials and operational application. Modern robotic welding services can automate much of the process, allowing manufacturers to produce highly complex welded assemblies at a much lower price point.

Robotic welding processes also help ensure consistency and repeatability from one product to the next. This is crucial for the manufacturing of highly complex products which demand close tolerances.

Single-Source American Manufacturing for Custom Welded Assemblies

Stamped Products Incorporated delivers quality welding services along with a full range of contract manufacturing capabilities. As a complete solutions provider, we are able to offer a streamlined production plan for virtually any complex welded assembly.

Based In Gadsden, Alabama, SPI is a leading provider for Tier 1 and Tier 2 automotive stampings and weldments. Our company is also backed by decades of combined manufacturing experience for utility vehicle (UTV) and all-terrain vehicle (ATV) applications, the HVAC industry, consumer appliances, and agricultural equipment.

There are numerous different types of metal stamping presses commonly used throughout today’s industrial manufacturing world. Likewise, there are many unique stamping operations which are optimized for different types of products or different metalworking features.

Below, we discuss some of the most common designs of metal stamping presses along with their advantages. We also compare the many different metal stamping processes and the typical product applications thereof.

The Common Types of Metal Stamping Presses Compared

Mechanical Stamping Presses

Mechanical presses use an electric motor to generate energy. The kinetic energy is transferred and stored in a relatively massive mechanical flywheel, which in turn powers the punch-press system.

While not as powerful as their hydraulic press counterparts, today’s mechanical stamping presses are capable of delivering massive stamping force. Ratings typically range from 20 tons all the way up to 6,000 tons. These presses can be found in an array of sizes that range from approximately 20 to 6,000 tons. Mechanical presses are well-suited for both progressive metal stamping services and transfer press operations.

Mechanical Servo Stamping Presses

Mechanical servo presses differ from standard mechanical presses in that they utilize high capacity motors instead of flywheels. Servo presses offer increased manufacturing flexibility with the slide motion and positioning, stroke, and the press speed all being precisely controlled and programmable. They are powered by either a link-assisted drive system or a direct drive system.

Mechanical servo presses provide extremely high levels of instantaneous torque. Essentially, these machines are able to output maximum pressing force at any point within the stamping operation. Because of this, servo presses are the best-suited option for the stamping of high-strength metals.

Hydraulic Stamping Presses

Hydraulic presses differ from mechanical presses in that they utilize pressurized hydraulic fluid to apply force instead of a kinetic flywheel. The basic configuration uses two interconnected hydraulic cylinders: a large high-volume cylinder called the “ram” and a smaller low-volume cylinder called the “plunger”. As hydraulic fluid is displaced from the ram to the plunger, internal pressure within the cylinder ramps up to deliver up to ~10,000 tons of metal stamping force.

Common Metal Stamping Operations Include:

• Piercing (Punching) – Piercing or punching uses a press and die to create precise holes within the sheet metal workpiece.
• Blanking – Blanking is similar to the punching process, except that the punched components are the product and the remaining sheet metal is scrap.
• Draw – A die is precisely positioned beneath the sheet metal. The punch forces the sheet metal down onto the die. The metal is deformed around the die to create complex cross-sections.
• Stenciling – Stamping one side of the workpiece creates raised or indented words, figures, and designs into the sheet metal.

Complete Metal Stamping Services with a Full Line of Transfer and Progressive Presses

SPI utilizes a wide range of presses to provide both the flexibility and efficiency that your commercial metal stamping project demands. Our in-house stamping department is integrated with transfer presses, progressive die presses, and hand transfer lines.

Automated Feed Presses:

• Seyi 660 Ton Servo Transfer
• Seyi 660 Ton
• Seyi 440 Ton
• Seyi 330 Ton
• Stamtec 660 Ton
• Warco 500 Ton
• Niagara 500 Ton
• Niagara 400 Ton
• Niagara 300 Ton
  

Secondary Stamping Presses:

• Clearing 500 Ton
• Verson 200 Ton (3)
• Verson 150 Ton (2)

The Single-Source Metal Stamping Company for Central Alabama and Beyond

SPI delivers quality metal stamping services in addition to our complete range of contract manufacturing capabilities. We offer decades of combined experience in the completion of industrial metal stamping projects for a wide range of commercial applications. Based In Gadsden, our facility is a premier supplier of Tier 1 and Tier 2 automotive stampings, as well as quality stamped products for utility vehicles, the HVAC industry, consumer appliances, and agricultural equipment.

Robotic welding services provide a number of distinct advantages when compared to conventional manual welding methods. Robotic welding systems are automated using highly articulated robot arms which lay the welds with nearly perfect accuracy and repeatability. The entire system is precisely controlled with custom programming developed for each unique product.

Stamped Products Incorporated provides extremely efficient automated welding services for the manufacturing of complex parts, components, and welded assemblies. Our robotic welding systems provide the superior quality and consistency that today’s precision products demand.

The Advantages of Robotic Welding Services

• Automated welding offers a higher degree of accuracy and repeatability with minimal human input.
• Robotic welding is much faster, providing reduced lead times and/or higher capacity for high-volume welding projects.
• Automation can substantially reduce the labor costs associated with your project.

Automated Manufacturing Offers Both Speed and Efficiency to Your Project

Automated welding services are generally much faster and more cost-efficient than traditional manual welding methods. SPI’s robotic welding technology is capable of much higher throughput than manual welding lines. This substantial increase in productivity allows us to provide your project with quicker turnaround and higher capacity.

The efficiency of our automated welding line makes the entire process less wasteful and more sustainable, minimizing material usage at every level. The robotic welding system carefully controls beads to use the least amount of filler material. Any weld splattering effects are also reduced, yielding the cleanest welds possible. Which leads into the next advantage of automated welding:

Superior Welding Quality and Consistency

Robotic welding systems are able to perform extremely accurate spot welds repeatedly for hundreds or thousands of products, making virtually no mistakes in the process. Robotic structural welds are performed with absolute repeatability from one component to the next, guaranteeing the consistent thickness, strength, and reliability for your products.

SPI’s state-of-the-art robotic weld systems virtually remove the element of human error from the manufacturing process. Nevertheless, our expert welding technicians are integral to the process – developing an optimized design and programming for your project while carefully monitoring the manufacturing process and results. Our entire facility operates under the strict quality control protocols of ISO 9001:2015 certification.

The Leading Robotic Welding Company for Central Alabama and Beyond

SPI delivers cutting-edge robotic welding services in addition to our complete range of contract manufacturing solutions. Our company specializes in commercial welding projects for consumer appliance parts, panels, and related components. Based In Gadsden, our facility is a premier supplier of Tier 1 and Tier 2 automotive weldments, as well as quality products for utility vehicles, the HVAC industry, consumer appliances, and agricultural applications.

Stamped Products Inc. (SPI) specializes in the contract manufacturing of metal stamped appliance parts, panels, and related components. Backed by more than 60 years of mass production experience, SPI offers versatile expertise within the consumer appliance sector that is unmatched by our competitors. Additionally, our company is an ISO 9001:2015 certified American manufacturer offering superior quality with every product that we make in-house.

Specialized Contract Manufacturing for the Consumer Appliance Sector

Since 1962, SPI has provided appliance OEMs with high quality in-house metal stamping services. Our services include progressive and transfer presses for metal stampings for the appliance industry.

Whether your project requires metal stampings or welded assemblies, SPI has the equipment and experience to get the job done.

Progressive Metal Stamping Services for Complex Appliance Components

SPI’s full-service progressive die stamping department is optimized to complete high-volume runs of consumer appliance parts. Our highly efficient progressive stamping solutions combine multiple pressing operations into a single pass to ensure maximum accuracy and repeatability. Additionally, we operate an in-house toolroom for building and maintaining the progressive tooling required for complex appliance stampings. 

Transfer Press Stamping Solutions for Large Appliance Parts and Panels

SPI’s facility includes a full-service transfer press department capable of processing  appliance panels and parts up to 32” in size. Our blank-fed transfer press provides a 660-ton capacity to accommodate appliance stamping runs when progressive presses are not capable.

Our Appliance Manufacturing Experience Includes:

• Refrigerators and freezers
• Clothing washers and dryers
• Dishwasher parts
• Grills, ovens, and racks
• HVAC systems and related components

Quality Metal Stamped Parts for Consumer Appliances

• Complex assemblies and subassemblies
• Custom stamped panels – doors, shields, and instrument panels
• Brackets and mounting solutions
• Appliance frames and structural components

The Leading Appliance Metal Stamping Supplier for Central Alabama and Beyond

SPI specializes in providing quality contract manufacturing services for consumer appliance parts, panels, and related components. Located in Gadsden, our state-of-the-art facility is a leading supplier of consumer and commercial appliance metal stampings for the Central Alabama region and beyond.

Stamped Products Inc. (SPI) is proud to be one of Gadsden, Alabama’s premier metal stamping facilities. We provide superior industrial stamping and automated welding services, as well as value-added assembly solutions. We are excited to announce the launch of our new website, which better reflects our innovative capabilities and experience.

A Strategic Metal Stamping Partner

SPI specializes in providing medium to high-volume metal stamping services for a wide range of commercial and industrial applications. Our diverse stamping experience includes:

• Precision stamped automotive parts, components, and assemblies.
• Custom stampings for the utility vehicle (UTV) / all-terrain vehicle (ATV) industries.
• Agricultural equipment and stamped products for the heavy equipment sector.
• Major appliances, as well as custom stamped HVAC components.

Our state-of-the-art facility integrates some of the industry’s most capable progressive presses and transfer die stamping systems:

• Variable speed presses from 300 ton to 660 ton.
• Progressive presses outfitted with servo feed lines.
• 660T press equipped with a linear servo transfer system and blank feeder.

Fully Integrated Robotic Welding Services

Additionally, our facility includes a full-service robotic welding department, Our automated welding solutions enabling us to streamline your project from start to finish – whether it involves simple metal stampings or complex welded assemblies.