Stage Tooling vs Progressive Tooling

Stage tooling and progressive tooling are common manufacturing approaches to metal stamping, with each having its benefits. In this article, we will discuss the details of each approach, as well as highlight the differences between stage tooling vs progressive tooling.

What is Stage Tooling

Stage tooling, often referred to as short-run metal stamping, is a metal-shaping process that utilizes multiple tools within a single press to produce components. Each stage of operation involves changing the tooling between processes, allowing for flexibility in creating both simple and complex parts. This method is especially beneficial for low-volume production runs, where affordability and efficiency are paramount.

Types of Stage Tooling

• Single-stage Tooling: This stage tooling involves performing one operation per stroke of the press. The part is either manually or robotically loaded to the die, the operation is then performed, and the part is removed. This method often serves in simple operations and is particularly suitable for high-mix, low-volume production scenarios. This is particularly due to the importance of flexibility and a lower upfront investment in these scenarios.

• Multi-Stage Tooling: In contrast to single-stage tooling, multiple tools are utilized sequentially. This approach enhances design flexibility and allows for the creation of intricate components without the need for excessive investments in tooling.
• Transfer Tooling: Although not strictly a type of stage tooling, transfer tooling often shares similarities. This method incorporates multiple steps in a single operation but transfers the part between various tools, allowing advanced capabilities for both simple and complex shapes.

Advantages of Stage Tooling

• Cost-Effectiveness: With lower initial setup costs compared to progressive tooling, stage tooling is exceptionally suitable for projects with limited budgets.

• Design Flexibility: The ability to revise or adjust tooling between operations grants designers the freedom to explore unique part geometries without significant delays.

• Simplicity of Setup: Stage tooling requires fewer complex setups vs progressive tooling, thus, easier to manage and transition between jobs.

• Precision and Control: This method provides excellent control over each operation, ensuring tight tolerances and high-quality outcomes.

• Low Volume Production: It is particularly effective for low to medium production volumes. Because it enables manufacturers to produce components efficiently without committing to extensive tooling investments.

Limitations

• Slower Production Rates: As each part must go through multiple setups, stage tooling is generally slower vs progressive tooling. Thus, it is not suitable for high-volume applications.
• Higher Per-Part Costs: While initial tooling costs are low, the per-part cost tends to be higher than in alternative methods. Especially as the volume of parts increase.
• Labor-Intensive: Due to the multiple tool changes necessary, stage tooling can be more labor-intensive. So, it always requires skilled operators to ensure precision and reduce the potential for errors.

Applications of Stage Tooling

• Complex Part Geometries: Single stage dies are particularly well suited for creating complex shapes. Since the part is not attached to a carrier strip, it can be manipulated more freely.
• High-Mix, Low-Volume (HMLV) Manufacturing: Stage tooling is a practical solution for producing a variety of parts in smaller quantities.
• Prototyping and Custom Parts: Ideal for testing part designs before committing to full-scale production. Because it allows for rapid revisions to tooling without significant cost implications.

What is Progressive Tooling

Progressive tooling represents an innovative process in metal stamping, designed to produce high volumes of parts efficiently. Using a series of stamping stations arranged within a single die, progressive tooling allows the continuous feeding of metal strips through the press, performing multiple operations such as bending, cutting, and piercing in a single sequence.

Benefits

Progressive tooling boasts several advantages that make it a preferred method for many manufacturers:

• High Production Rates: The efficiency of continuously feeding metal strips leads to fast production speeds, often exceeding hundreds of parts per minute.
• Lower Cost Per Part: Although the initial setup costs are high, progressive tooling drastically reduces costs per part when producing large volumes, making it cost-effective in the long run.
• Minimal Scrap Material: Progressive die design allows it to maximize material use, significantly reducing scrap rates and minimizing waste.
• Consistency in Quality: With each part undergoing the same processing sequence under controlled conditions, progressive tooling ensures high repeatability and tightly controlled tolerances.
• Ability to Create Complex Geometries: This method excels in producing parts with intricate designs and multiple features, all achieved in a single pass.

Limitations

While progressive tooling is advantageous, it also has its challenges:

• High Initial Tooling Costs: The investment required to create permanent steel dies can be substantial. Thus, making it less suitable for low-volume production runs.
• Complex Design Requirements: Designing the die set requires careful consideration of part geometry and material flow. Hence, making it a complex process.
• Limited Flexibility for Changes: Once set up, altering the design for new projects can be time-consuming and costly. Therefore, reducing the method’s adaptability.

Progressive Tooling Applications

Progressive tooling is ideal for high-volume production runs in various industries, including:

• Automotive Components: Frequently used for manufacturing small, precise components like brackets, clips, and connectors.
• Electronics Industry: Beneficial for creating intricate parts such as battery connectors and circuitry components, where precision is vital.
• Consumer Goods: Effective for producing items such as appliance parts and decorative metal components that require high volumes and consistent quality.

Differences Between Stage Tooling vs Progressive Tooling

Having explored both stage tooling and progressive tooling individually, it is important to understand the key differences between the two methods.

Parameter	Stage Tooling	Progressive Tooling
Production Volume	Suitable for low to medium-volume production runs.	Ideal for high-volume production, capable of producing thousands of parts quickly and efficiently.
Cost Structure	Lower initial setup cost, but higher per-part costs in large runs.	Higher initial costs with tooling, but significantly lower per-part costs for large-scale production.
Complexity and Design Flexibility	Offers more design flexibility with the ability to adjust tooling between setups, although it may be limited in handling very complex geometries.	While capable of producing complex parts, it requires a precise initial setup and is less adaptable to changes without incurring costs.
Production Speed	Generally slower due to multiple setups and operations.	Fast and efficient, with continuous operation leading to high throughput.
Labor Intensity	More labor-intensive as it requires skilled operators to manage frequent tool changes.	Less labor-intensive during operation, as fewer operators are needed for supervision of machines running unattended.

Stage and Progressive Tooling at ITD

No matter what the fabrication needs are for delivering premium parts for your application, we’ve got you covered at ITD. Our ever-increasing equipment list includes an array of stage and progressive tooling, setting us apart as one of the leading contract metal stampers in the industry. Contact us today for more details on delivering the best value for your project.