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Progressive Die Stamping of a Steel Bracket Assembly for the Automotive Industry

Progressive Die Stamping of a Steel Bracket AssemblyPerfection Spring & Stamping Corp. was contracted to manufacture a large series of steel bracket assemblies for the automotive industry. This bracket assembly consisted of three mounting legs per component and a cover bracket that was originally die casted. Through prototyping and development testing, our team of engineers established that this expensive die casting process could be replaced with drawn metal stamping operations. This solution provided better product at considerable cost savings!

Offering a more stable metal forming procedure, drawn metal stamping eliminated the need for other secondary operations and fasteners. Moreover, with the ability to maintain tighter tolerances - as well as provide better transfer of heat in extreme temperatures to meet the customer's RFI/EMI requirements - this process yielded a higher quality product. Additionally, the progressive die replaced the need for expensive maintenance costs associated with die cast tooling. When the results were tabulated, this solution generated an annual cost savings equal to $200,000 per year over the five-year program, providing our customer with a total savings of $1,000,000.


Progressive Die Stamping Project Highlights of a Steel Bracket Assembly

Product Description This Bracket Assembly consists of the mounting legs (3 per) and the cover bracket and was originally die casted. We came up with a drawn metal stamping solution for cost savings.
Capabilities Applied/Processes Progressive Die Stamping
  • Lock Three Mounting Legs to Cover Bracket
Equipment Used to Manufacture Part Brown Boggs Punch Press
  • 200 Ton & 600 Ton
  • Up to 12 Stations
Overall Part Dimensions
Mounting Legs:
Material Thickness: .065"
Length: 1.25"
Width: 1.50"
Height: 1.40"
Cover Bracket:
Material Thickness: .040"
Length: 8.50"
Width: 4.50"
Height: .75"
Tightest Tolerances ±.0005"
Material Used Cold Rolled Steel Draw Quality
  • 1008/1010 DQ
Finish Zinc Nickel Yellow Chromate
Engineered Cost Savings to Eliminate Die Casting
More Stable Metal Forming Process
Elimination of Secondary Operations
Tighter Tolerances Maintained
Better Transfer of Heat to meet RFI/EMI Requirements
In Process Testing/Inspection Performed
In-Process Real-time SPC of Critical Dimensions
CMM Measurement
Torque Testing
Salt Spray Testing
Dimensional Results Reporting
Control Plan
Process Flow Diagram
Failure Mode and Effects Analysis (FMEA)
Gage Repeatability and Reproducibility Variable Data Report
Raw Material Chemical Composition Results
MSDS - Material Safety & Data Report / Substances and Materials
Estimated Part Weight Mounting Legs: .11 lbs
Cover Bracket: 1.20 lbs
Industry for Use Automotive
Volume 1,000,000
Packaging Custom Corrugated Cell Packaging
Lead Time Tooling: 15 Weeks
Production Parts: 6 Weeks
Delivery Location Alabama
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Steel Bracket Assembly

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