Creating small metal components demands specialized techniques where precision, efficiency, and material integrity are non-negotiable. From medical devices to micro-electronics, these tiny parts power innovation. There are some ways about how they're made and why the stamped metal parts dominate high-volume production:
1. Metal Stamping
Stamping is a forming process that uses a press and dies to apply external pressure to materials such as plates, strips, tubes and profiles, causing them to undergo plastic deformation or separation, thereby obtaining workpieces of the required shape and size. Stamping and forging both belong to plastic processing (or can be called pressure processing), collectively known as forging and pressing. The blanks for stamping are mainly hot-rolled and cold-rolled steel plates and steel strips. Of all the steel in the world, 60 to 70 percent is sheet steel, and the majority of it is formed into finished products through stamping. For instance, from large components such as the body, chassis, fuel tank and radiator fins of a car to small ones like the steam drum of a boiler, the shell of a container, and the silicon steel sheets of the cores of motors and electrical appliances, all are processed by stamping. There are also a large number of stamped parts in products such as instruments and meters, household appliances, bicycles, office machinery, and household utensils.
Advantages:
- Speed and scale: The speed selection of slow stamping and fast stamping, a variety of processing materials to choose from, and low mold cost loss.
- Precision complexity: Progressive dies can process complex geometers (with extremely low tolerances, up to 0.1mm+), and can also integrate multiple functions - holes, flanges, embossing - on a single device assembly.
- Cost efficiency: If almost zero waste is achieved through nesting; The cost of each piece after processing has been greatly reduced.
Therefore, stamping metal parts, such as electrical contacts, sensor shielding and implantable device components, are dominant examples of this method.
2. CNC Machining
CNC Numerical Control (Computerized Numerical Control) is a technology that controls the movement and processing of machine tools through computer digital information, replacing the traditional manual operation of machine tools. Its core equipment, the CNC machine tool, is composed of a CNC device, a programmable controller, a spindle drive and a feed device, etc., covering the integration of multiple fields such as mechanics, electricity, hydraulics, pneumatics and optics.
In terms of efficiency: Multiple processes such as drilling and milling can be completed in a single clamping, significantly enhancing efficiency and accuracy.
In terms of precision: Superior tolerance (±0.025mm) and foreign alloys.
3. Metal Injection Molding (MIM)
Metal Injection Molding (MIM) is a new near-net-shape forming technology that combines plastic injection molding with powder metallurgy and was invented in 1973. Its process flow includes steps such as mixing metal powders with binders, injection molding, degreasing and sintering. It can produce high-precision and complex three-dimensional structured metal parts, with material particle sizes ranging from 2 to 15μm and product relative density exceeding 95%. It is widely used in electronics, automobiles, medical and other fields
4. Laser Cutting
Laser cutting usually utilizes the high temperature after laser focusing to cause the material to be processed to melt or evaporate rapidly, thereby completing the cutting process of the material. This processing procedure features high speed, high precision and smooth and neat cut surfaces.
Rapid prototyping of flat components (shims, filters, circuit shields).
Fine features (0.1mm slots) with minimal burring.
5. Micro-Machining
Micro-machining is a precise and ultra-precision processing technology that takes ultra-micro drill bits as the core tool and is carried out for hole diameter characteristics ranging from 0.01 to 1mm. This technology is widely applied in the manufacturing of precision components such as micro-holes in printed circuit boards, fuel injectors, and medical titanium alloy filters. It requires that the dynamic runout error of the machine tool spindle be controlled within 0.0025mm, and the comprehensive runout accuracy of tool clamping reach the 0.001mm level.
The manufacturing of small metal parts requires the selection of the most suitable process based on the processing material, volume, thickness, shape, complexity and cost. Stamping small metal parts can provide efficient production capacity and certain precision for large-scale production, while CNC, MIM and laser methods are more suitable for high-precision processing, and the corresponding prices are slightly higher. If cost, benefit and efficiency are taken into account, stamping small metal parts will be the best choice.
