| Progressive Die Design and Manufacturing | Integrated die stations perform successive operations, such as piercing, bending, forming, and part cut-off, as strip material advances through the tool. | High-volume production of small and medium stamped components, including brackets, reinforcements, and electrical or seat hardware. | Die layout, strip layout, tool design, tryout support, and checks for part dimensions, burrs, and repeatability. |
| Transfer Die Systems | Parts are moved between forming stations by mechanical or robotic transfer equipment, allowing multiple operations on larger or deeper parts. | Structural panels, chassis components, and other parts that are not suited to conventional progressive-strip production. | Station and transfer concepts, die sets, operation sequencing, and trial-run checks for part handling and forming consistency. |
| Tandem and Line Dies | Separate dies carry out individual operations in a press line, with parts transferred between presses or stations. | Large body panels and components requiring several forming, trimming, piercing, or flanging operations. | Individual dies, process planning, line integration support, and dimensional inspection of trial parts. |
| 3D CAD and Die Simulation | Digital design and forming analysis help assess material flow, thinning, wrinkling, springback, and potential forming issues before production tooling is finalized. | Complex body-in-white panels, high-strength steel parts, and components with demanding geometry. | 3D tool designs, forming analysis reports, process recommendations, and design revisions based on simulation results. |
| High-Strength Steel Forming | Tool and process design accounts for the higher strength and springback behavior of advanced high-strength steels and other demanding sheet materials. | Safety-related structural parts, reinforcements, pillars, and chassis components. | Material-specific process plans, compensation strategies, trial results, and dimensional verification against supplied specifications. |
| Aluminum Sheet Forming | Forming methods and tool surfaces are selected to address aluminum’s material behavior and reduce risks such as surface marking and cracking. | Lightweight body panels and structural components made from sheet aluminum. | Material and lubrication recommendations, forming trials, surface-condition checks, and dimensional inspection. |
| Tryout, Sampling, and Tool Tuning | Press trials are used to evaluate the tooling and adjust forming conditions, clearances, or tool geometry as needed. | New dies, transferred tools, and production changes that require confirmation before release. | Trial parts, issue lists, adjustment records, and sample inspection results. Scope depends on the agreed project plan. |
| Metrology and Dimensional Inspection | Parts and tooling features are measured against engineering drawings or agreed inspection requirements using suitable measurement equipment. | Prototype, pre-production, and production validation for stamped components. | Measurement reports, dimensional comparison data, and documentation of nonconformities where applicable. |
| Tool Repair, Maintenance, and Refurbishment | Inspection, repair, replacement, or adjustment of worn or damaged die components to support continued production. | In-service tooling requiring corrective work, scheduled maintenance, or relocation support. | Repair plans, replacement components, maintenance records, and post-repair trial or inspection support. |
| Engineering Change and Localization Support | Tooling or process updates are managed when part designs, materials, manufacturing locations, or customer requirements change. | Model-year updates, design revisions, and production transfer projects. | Change assessments, revised tool data, updated documentation, and validation samples as defined by the project. |