There are various ways to create shapes in metals. The method used to create the part, component or shape will depend on several factors including the size of the desired component, the type of metal and the specific requirements for the components. There are only a few shops left in Boston and throughout the country that offer all of these different processes.
One of the most common options used in forming complex shapes in metals, particular aluminum, is to use an extrusion process. The aluminum is heated to a semi-liquid form and forced through a specially designed die to create a shape.
Another process that is used with different types of metals and alloys is stamping. Copper stamping is highly effective because it allows for the rapid production of different sizes of parts that can be completely repeatable to very tight tolerances.
The Process
For both prototype parts as well as production runs, the first step in the copper stamping process is to design a CAD(computer aided design) program that models the prototype part desired. This allows the computer to create the die that will produce a completely accurate part.
For deep drawn copper the metal is first blanked. This means it is cut into specific lengths and sizes that are based on the final part size. The shapes will either round of flat for the blanks.
These blanks are then processed through the copper stamping machine. Depending on the complexity of the parts there can be a series of different die used to shape the final component.
After the part is shaped, additional requirements for holes or other features are produced using punches or boring. The part is then processed as needed to provide the desired end product.
The Benefits
There are several benefits to stamping copper. With the stamping the copper itself becomes work hardened, which means it will be stronger and more durable after stamping than it was before the process began.
Stamping is fast and effective in making simple to very complex shapes and parts. As the copper is in one piece, it is naturally stronger than if it is fabricated to create the shape. With automation of the stamping process in Boston shops and the high degree of accuracy of each part, this is an excellent option for producing small and large volume part orders quickly and at a very reasonable cost.
