Key Questions to Ask When Ordering Sheet Metal Stamping Die

Sheet Metal Stamping is a low-cost high-speed manufacturing process that produces a high volume of identical metal components, which has contributed importantly to many industrial applications such as vehicles, equipment, electronics, appliances, tools, and so much more. For example, sheet Metal Stamping provides a large number of wholesale machine parts for Mechanical Industry.

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At AM Industries Vietnam, our experts can produce highly detailed custom sheet metal stampings and components that meet all customer design specifications. We serve customers across all industries and deliver short- to medium-run metal stampings and sheet metal prototyping for parts and components of all sizes and shapes.

To learn more about our precision metal stampings and custom steel fabrication capabilities, speak with an expert or give us an at , and we'll gladly answer your specific questions.

What is Sheet Metal Stamping?

Sheet Metal stamping is a cold-forming process that uses dies and stamping pressing machines to shape sheet metal into various forms. Pieces of flat sheet metal typically referred to as blanks, are fed into a sheet metal stamping press that uses a tool and dies surface to transform the metal into a new shape. The material is placed to be stamped between die sections, where the use of pressure will form and shear the material into the desired final shape for the product or component.

Stamping operations are suitable for both short or long production runs, and be conducted with other metal forming operations, and may consist of one or more of a series of more specific processes or techniques that we will mention below.

With stamping presses built to handle capacities up to 440 tons and precision stamping dies and tooling that we make in-house, we can create parts as thin as 0.005' while maintaining tolerances that often exceed industry standards.

Basic techniques of Sheet Metal Stamping

Metal stamping machines may do more than just stamping; they can cast, punch, cut, and shape metal sheets. Machines can be programmed or computer numerically controlled (CNC) to offer high precision and repeatability for each stamped piece. Electrical discharge machining (EDM) and computer-aided design (CAD) programs ensure accuracy

Blanking

Blanking is a steel manufacturing process in which a flat, geometric shape (or 'blank') is created by feeding a coil of sheet metal into a press and die. The blank is punched out from a large metal sheet in this process. Here's a graphic representation of the process:

Piercing

If a part requires slots, holes, or other cutouts, piercing can be employed. Piercing, which can be performed simultaneously with blanking, punches the requisite shapes out of the metal sheet.

Punching

CNC punching is an important option for generating sheet metal blanks. Punching is an inherently faster operation that lends itself to metal fabrications that have many similar features or where there is a higher volume of parts per run.

Embossing

Metal embossing is used to impart a design upon metal sheets. The metal is pushed with an embossing tool or stylus to create a raised effect on the opposite side. By placing the metal sheet on a rubber or foam pad, the positive impression has a smooth surface that will shine or can take pigment.

Bending

Bending refers to the general technique of forming metal into desired shapes such as L, U, or V-shaped profiles. The bending process for metal results in a plastic deformation that stresses above the yield point but below the tensile strength. Bending typically occurs around a single axis.

When you are designing the bends into your stamping metal part, it is important to allow for enough material ' make sure to design your part and its blank so that there is enough material to perform the bend. Some important factors to remember:

• If a bend is made too close to the hole, it can become deformed.
• Notches and tabs and slots should be designed with widths that are at least 1.5x the thickness of the material. If made any smaller, they can be difficult to create due to the force exerted on punches, causing them to break.
• Every corner in your blank design should have a radius that is at least half of the material thickness.
• To minimize instances and severity of burrs, avoid sharp corners and complex cutouts when possible. When such factors cannot be avoided, be sure to note burr direction in your design so they can be considered during stamping

Coining

Coining is a bending technique wherein the workpiece is stamped while placed between a die and the punch or press. This action causes the punch tip to penetrate the metal and results in accurate, repeatable bends. The deep penetration also relieves internal stresses in the metal workpiece, resulting in no spring-back effects.

Flanging

Flanging is the process of introducing a flare or flange onto a metal workpiece through the use of dies, presses, or specialized flanging machinery.

Custom Sheet Metal Stampings Material Options

We work with a wide range of custom materials for your projects. If you don't see your preferred material option listed below, contact us to discuss your project's specific requirements.

• Carbon Steel
• Cold Rolled Steel
• Hot Rolled Steel
• Galvanized Steel
• Stainless Steel
• Aluminum
• Beryllium Copper
• Brass

Custom Sheet Metal Stamping

Our Custom Sheet Metal Stamping service provides metal forming processes that apply custom tooling and techniques to produce parts specified by the customer. We could offer a wide range of industrial and application parts and components that employ custom stamping processes to meet high-volume production needs and ensure all parts meet exact specifications.

Custom Sheet Metal Stamping Projects

Our engineers can work on a wide range of sheet metal part projects for clients across various industries. To better illustrate the versatility of custom stamped metal parts, we've outlined a few recent projects completed by AM's engineers below.

Custom Stamped Part for mounting brackets in the automobile industry

An American client in the automobile industry approached AM to make their custom metal stamps with special requirements for their vehicle-specific kits.

They needed custom stainless steel brackets with no sharp edges at the final products and were having trouble finding a supplier who would provide a high-quality design at an affordable price within a reasonable timeline.

To meet the client's unique request for precise thickness and the complex design requirements, we used a material blanking and bending technique that allowed us to create a smooth surface and exact shape as designed, limiting costs and reducing lead times.

Stamped Cable Tray for a Wiring and Cable Application

In another instance, we were asked to remake an existing electrical cable tray; our client was looking for a higher-quality product at a lower price with shorter lead times.

The design was not highly complex, but this application includes a number of small parts, therefore it inherently presented strict size limitations. The manufacturing process was complicated and expensive, as some of the client's jobs required a fully completed powder coating and others did not.

Working with a sample tray, our team at AM was able to reverse engineer the part and its tool. From here, we designed a new stamping die set that allows us to manufacture the parts easier and lower cost.

See more our case studies here: https://aminds.com/case-studies/

Types of Stamping Operations

Progressive die stamping

Progressive die stamping uses a type of tooling called a progressive die, which contains multiple stamping stations to carry out simultaneous operations on a sheet metal strip. By combining all the necessary tools into one die set, progressive die stamping is a great solution for high-volume production runs.

Transfer Die Stamping

Transfer die stamping is similar to progressive die stamping, but the part is separated from the metal trip early on in the process and is transferred from one stamping station to the next by another mechanical transport system, such as a conveyor belt. This process is usually used on larger parts that may need to be transferred to different presses.

Four-Slide Stamping

Four-slide stamping is also called multi-slide or four-way stamping. This technique is best-suited for crafting complex components that have numerous bends or twists. It uses four sliding tools, instead of one vertical slide, to shape the workpiece through multiple deformations. Two slides, or rams, strike the workpiece horizontally to shape it, and no dies are used. Multi-slide stamping can also have more than four moving slides.

Four-slide stamping is a very versatile type of stamping, as different tools can be attached to each slide. It also has a relatively low cost, and production is fast.

Fine Blanking

Fine blanking, also known as fine-edge blanking, is valuable for providing high accuracy and smooth edges. Usually done on a hydraulic or mechanical press, or by a combination of the two, fine blanking operations consist of three distinct movements:

• Clamping of the workpiece or work material in place
• Performance of the blanking operation
• Ejection of the finished part

Fine blanking presses operate at higher pressures than those used in conventional stamping operations, hence tools and machinery need to be designed with these higher operating pressures in mind.

The edges produced from fine blanking avoid fractures as produced with conventional tooling and surface flatness can exceed that of other stamping methods. Since it is a cold extrusion technique, fine blanking is a single-step process, reducing the overall costs of fabrication.

Deep Draw Stamping

Deep drawing involves pulling a sheet metal blank into the die via a punch, forming it into a shape. The method is referred to as 'deep drawing' when the depth of the drawn part exceeds its diameter. This type of forming is ideal for creating components that need several series of diameters and is a cost-effective alternative to turning processes, which typically require using up more raw materials. Common applications and products made from deep drawing include:

• Automotive components
• Aircraft parts
• Electronic relays
• Utensils and cookware

Short Run Stamping

Short-run metal stamping requires minimal upfront tooling expenses and can be an ideal solution for prototypes or small projects. After the blank is created, manufacturers use a combination of custom tooling components and die inserts to bend, punch or drill the part. The custom forming operations and smaller run size can result in a higher per-piece charge, but the absence of tooling costs can make short-run more cost-efficient for many projects, especially those requiring fast turnaround.

Stamping Advantages and Disadvantages

Sheet metal stamping has several advantages including lower die costs, lower secondary costs, and a high level of automation compared to other processes. Metal stamping dies are less costly to make and maintain than dies used in other typical operations. Cleaning and plating are also less expensive than identical treatments for other metal manufacturing techniques. Stamping machines are generally simple to automate and may use sophisticated computer-control systems to give more precision, faster output, and shorter turnaround times. The high level of automation also reduces labor costs.

One of the disadvantages of stamping is the higher cost of presses. The dies must also be acquired or created and producing custom metal stamping dies is a longer pre-production process. Dies can also be difficult to change if the design must be altered during production.

Precision Quality Stampings & Fabrication

We produce only the highest quality custom metal stampings. Our workforce is dedicated and committed to quality through Quality Circle involvement. Our products are high-quality and are certified to ISO : certified, AU, US, EU, or CA standards.

Sheet Metal Stamping Applications

Stamping parts are used in a variety of applications, especially those involving three-dimensional designs, lettering, or other surface engraving features. Such stamping products are commonly produced for home appliance manufacturers, automotive companies, the lighting industry, telecommunications services, military and defense, aerospace industries, medical equipment manufacturers, and electronics companies. Odds are you have a product in your home that has parts created through metal stamping because it is a process used in everything from your household appliances to your cars.

The specific products and components can range from simple stamping items, such as metal clips, springs, weights, washers, and brackets, to more complex designs, such as those found in engine bases or friction plates. This process is used for producing both parts for large machinery and also incredibly detailed small parts. Micro-precision stamping can create parts with diameters of up to 0.002 inches.

Electronic stampings are electronic components manufactured through the metal stamping process. They are used in a variety of industries, from home electronics and appliances to telecommunications and aerospace. Electronic stampings are available in several metals, including copper, copper alloys, aluminum, and steel, as well as more expensive metals, such as platinum and gold. Electronic components produced by the metal stamping method include terminals, contacts, lead frames, springs, and pins. They can be created from ferrous or nonferrous materials. Metal stampings find wide use in computers, electronic equipment, and medical devices. Because of the specialized shapes that can be made by the various stamping processes, many electronics are made by this cold forming process.

Design Concepts

Overly narrow projections should generally be avoided in stamped products, as these may be more easily distorted and impact the perception of quality in the finished product.

Where possible, designs should be based on the use of existing dies for standard shapes and bends. The need to create a custom die for stamping will increase initial tooling costs.

Avoidance of sharp internal and external corners in stamped product designs can help reduce the potential for the development of larger burrs in these areas and sharp edges that require secondary treatment to remove. Also, a great potential for stress concentrations exists in sharp corners, which may cause cracking or subsequent failure of the part through extended use.

Overall dimensions for the finished product are going to be limited by the available dimensions of the sheet metal sheets or blanks, and these limits need to be factored in for the material consumed in folds on edges or flanges and any additional material removal or use. Very large products may need to be created in multiple steps and mechanically joined together as a second step in the production process.

For punching operations, consider both the direction of punching as well as the size of the punched feature. Generally, it is best to do punching in one direction, so that any sharp edges produced by the punch will all be on the same side of the workpiece. These edges can then be hidden for appearance purposes and kept away from general access by workers or product end-users where they might represent a hazard. Punched features should reflect the thickness of the raw material. A general rule is that punched features should be at least twice the material thickness in size.

For bends, the minimum bend radius in sheet metal is roughly the same as the material thickness. Smaller bends are more difficult to achieve and may result in points of stress concentration in the finished part that may subsequently cause issues with product quality.

When drilling or punching holes, performing these operations in the same step will help to assure their positioning, tolerance, and repeatability. As general guidelines, hole diameters should be no smaller than the material thickness, and the minimum spacing of holes should be at least twice the material thickness apart from each other.

Bending operations should be performed with awareness of the risk of distorting the material, as the material on the interior and exterior surfaces of the bend point are compressed and stretched respectively. The minimum bend radius should be approximately equal to the thickness of the workpiece, again to avoid stress concentration build-up. Flange lengths should be more like three times the workpiece thickness as a good practice.

Contact us for Precision Sheet Metal Stampings and More

Are you searching for a reliable precision sheet metal stampings manufacturer at a reasonable cost? Look no further than AM Industries Vietnam. Request a quote on your custom sheet metal stamping project or contact us to find out what we can do for you.

'Cutting' might be a misleading word. Melting is actually more accurate. In order to melt the face of pressure-sensitive vinyls, thermal dies use a combination of three factors: heat, dwell time, and pressure. However, thermal dies just 'kiss' the vinyl, leaving the paper liner, or carrier, intact. Please see Diagram #1.

Of course, different combinations of heat, dwell, and pressure are necessary for crisp, sharp 'cutting' of the various types of vinyls. With regards to heat, it is always best to start with lower temperatures, and work your way up gradually. For four-mil vinyl, your press temperature should be set at 275°F, and then gradually increased until a clean cut is achieved. Special attention has to be given when using layered screen printing and UV coatings. Higher temperatures are needed for reflective and screen-printed materials, ranging as high as 350°F.

Dwell times will vary according to the material and heat that you are using. One-half to two seconds is the norm for dwell time. Some people cut their dwell time down by using higher temperatures, using past experience as their guide.

The final factor, pressure, is greatly affected by the configuration of your die. Intricate details require relatively more pressure than large, open areas. Also, you may want to adjust the type of counter board underlay that is used depending on the image being cut. Commonly used counter board underlays are posterboard, chipboard, and polyurethane.

Keeping these three factors ' heat, dwell, and pressure ' in check will reduce the build-up of melted vinyl on the shoulders of your die, and give you a more stress-free cutting experience. It's important to remember that it is the combination of these three factors that allows thermal dies to melt or 'kiss-cut' vinyls.

Are you interested in learning more about Sheet Metal Stamping Die? Contact us today to secure an expert consultation!

Profile of a Good Thermal Kiss-Cut Die

Magnesium thermal dies are typically produced in two thicknesses. The most commonly used thickness for four-poster presses is 11 point (.153'). Then there is 18 point (.250'), typically used on clamshell presses. The size of thermal dies is only limited by your press size. Using our oversize die etching machine, OWOSSO can etch cutting images ranging from a single square inch to 10 feet long by 30 inches wide.

Obviously, the goal of using a thermal die is to precisely cut your customer's artwork. It's vital in matching this artwork to remember that heat (the thermal part of your die) expands all metals'including magnesium.

Magnesium expands approximately .25% at 290°F and .5% at 350°F. Higher temperatures will cause greater expansion. The Heat Expansion formula in Diagram #2 will help you, especially with critical registration.

If your job requires close registration, run a sample under actual conditions so that printing can be matched to the impression of the die registration. You can use carbon paper between the die and the counterboard underlay to create an impression of the expanded die.

Photoengraving demands craftsmanship. After the image is developed onto highly polished magnesium, every fine detail, every inch, must be inspected for broken lines, pinholes, or missing details. The magnesium is then etched in acid baths. Diluted nitric acid containing solvents and water is splashed against the image surface of the magnesium, etching away everything except the desired line image. The process has to be monitored for constantly changing acid concentrations, temperatures, and humidity, which all fluctuate depending on the amount of open areas of the image being etched.

All these factors influence the depth, shoulder angle, and cutting-edge width of a thermal die; whether it's a steep, sharp shoulder or sloping and wide.

The cutting edge for 2 mil to 4 mil vinyl should have a surface of .002' to .004', depending on the boldness of the image, or if imprinted vinyl is being used. The regular etching depth is between .060'-.075' for basic cutting needs. More depth can be achieved for special cutting requirements. Please note that only the first .010-.012 inches will actually do the cutting of your vinyl. The remainder of the die's depth will help prevent scorching of your substrate and build up of melted vinyls. It will also help avoid slow downs in cutting speed, and will keep the vinyl away from the heated die.

We can help you get the best results if we know what you're cutting. We can etch the dies deeper, or with steeper shoulders if necessary. Some examples of materials needing special attention are: preprinted, UV coated, static cling, and reflective vinyl.

Magnesium expands approximately .25% at 290°F and .5% at 350°F. Higher temperatures will cause greater expansion.

Cutting With Your Hot Kiss

Properly mounted dies on a well-maintained press hardly require make-ready since the surface of the die is of even height. An even counter board underlay, such as poster board, chip board or polyurethane will help in cutting, and it will also protect the edges of the die from dulling or smashing.
To prevent the melted vinyl from sticking and building up on die shoulders, use a release agent such as OWOSSO Release coating. This is an advanced Teflon-like release coating, which has better releasing properties than older spray-on types. Release coatings are most helpful on fine detail and difficult jobs. Even with the newer release agents you need to keep your heat settings in check. Too much heat will result in burned material, raised ridges on part edges, and, in some cases, cut parts that get heat-welded to their backing sheets.

By now you're probably wondering how many cutting impressions are possible with magnesium dies. Just as for steel rule dies, the material substrate and temperature being used contribute to the longevity of a die. For reflective vinyl with beads, a die might only last for 300 to 500 strikes. Contrast this with a report we've received from Houston about a company getting over a million impressions, on 2-mil vinyl ' and they're still using that same die. Trust us, this isn't just another tall tale from Texas!

Putting bearers around the die can prevent damage from too much pressure. When dies are mounted, they should be centered on the press plate as much as possible, so that even pressure is applied. If a die design has images that are lop-sided, off to one side, this creates an unbalanced load on the press. For more uniform cutting, place pressure bearers on the open side to compensate.

Please give OWOSSO a call when you are cutting unusual printed material or materials with heavy UV coatings. We can point out where you may experience trouble, and it will help you get a clean, sharp cut.

Thermal Die Maintenance
When finished cutting, it is best to remove the die from the press while it is still hot, gently prying it off (the hotter the die is, the easier it will come off). Take care not to let it fall face down. Before the die cools, use a natural-fiber brush to scrub off any residues. We recommend a tampico fiber brush, which can be found at most hardware stores. Dies are easier to clean while still at cutting temperature. To avoid magnesium corrosion, coat your die with an oil such as Pam' cooking spray. Of course, this prevention is not necessary if your dies are already coated with OWOSSO Release Coating. Dies last longer when stored in a low-moisture, chemical-free atmosphere.

Here are just a few more tips to remember: Magnesium is a soft metal; it is almost impossible to repair. A good method for storing thermal dies is to drill a hole at one end for hanging. Hanging your dies avoids warping, but you can just as effectively stack your dies by taping a protective sheet of chipboard over the face of the die. The die will stay straight and not be damaged when stacked. Although the cutting edges are not sharp, they need to be protected.

So Go Get a Hot Kiss!
Following these general guidelines will help make kiss-cutting a joy, rather than a job. Don't forget OWOSSO is always available for troubleshooting and free estimates. Vinyl manufacturers are also a great source for questions. And remember ' there's nothing like a 'hot kiss!'

Several important factors combine to determine the choice between brass, magnesium and copper for creating the best results with your foil stamping, embossing, and debossing dies. No single factor should be used alone to make the decision. Since all of the factors listed below interact with one another, their cumulative effect should be considered. Experience will help you make the best material choice, and your printer, press operator, and photoengraver can all provide valuable assistance.

Choosing magnesium, when appropriate, can yield cost savings for your customer and speed up turn-around, without sacrificing quality.

Brass dies are hand sculpted and machined therefore making them the most expensive of the three metal choices. Brass dies are the most durable and since they can be repaired, the life of the die is almost endless. Interpretation of the artwork is only possible with brass dies, including shapes, textures and edges.

Copper is a relatively harder metal used for the same applications as magnesium dies. If your job requires a more durable metal, copper is the best selection. Please consider the following:

• Surface Area Pressure
• Artwork Designs
• Length of Press Run
• Substrates
• Handling and Maintenance
• Experienced Craftsmanship

Surface Area of Pressure
The amount of pressure required to achieve the best results depends on the size of the surface area being foil stamped, embossed or debossed. Equal foil stamping, embossing and debossing results for a one-inch square surface area require less pressure than that needed for five square inches. Depending on the other factors involved, magnesium is best used on smaller areas with smoother papers while copper is beneficial for larger areas, more heavily textured papers, and extremely long runs. Brass is generally used for combination foil and embossing dies.

Artwork Designs
Durability of your foil stamping, embossing and debossing dies under pressure should suit your artwork design. Relatively more pressure is needed for the best results in bold and uniformly spaced designs. For example, a solid square requires more pressure than an outlined square of the same size. Fine detail and unevenly distributed artwork designs require relatively less pressure and can be readily achieved with magnesium. However, bold and evenly spaced artwork to be printed in long runs may require pressure that copper can withstand best.

Length of Press Run
Generally longer press runs can cause erosion on magnesium foil stamping, embossing and debossing dies. For this reason, copper dies are recommended for long runs. However this is a relative guideline since many factors determine what is even considered a long run. For example, heat is a factor that can reduce the durability of metal. Magnesium has achieved runs in the upper tens of thousands. If you are using high heat and have a long run with your foil stamping, embossing and debossing, brass or copper might be better choices.

Substrates
Is your paper stock recycled, heavily textured, coated, or uncoated? Generally, the tougher the paper stock, the more durable the metal for your die should be. Smoother paper stocks don't wear as much on your foil stamping, embossing and debossing dies, and magnesium can yield excellent results. Copper dies may be worth the extra cost when using heavily textured papers and for longer runs.

Handling & Maintenance
Press tolerances should be checked periodically. When adjusted accordingly, you can considerably increase the life of your foil stamping, embossing and debossing dies. Also, be careful in make-ready. Scratching and dents can be avoided with just a little attention. With proper handling in all of these areas, you will get more from your die. A good way to store your magnesium dies is to first coat them with a little cooking spray or oil such as Pam.' When stored and handled properly you may find you are using magnesium again and again.

You'll offer your customers the best cost, speed, and quality, when you balance all of the above factors. Paper houses have sample departments ' use them to test your dies on different stock. Artwork designers should also consult with printers and finishers concerning stock choices and designs. When printers and finishers know ahead of time what they will be working with, it is much easier for them to evaluate the best metal for your foil stamping, embossing or debossing job.

Experienced Craftsmanship
OWOSSO welcomes any technical questions or inquiries. Just fax (989-723-) or your job specifics including artwork design, length of run, paper stock, and temperature and we can help!

Since , OWOSSO continues to set the industry standard for both craftsmanship and service. Our experienced staff has a thorough knowledge of the substrates, the die-making process, and the best production techniques that produce the highest quality dies.

Facing Floody Print
Finishers repeatedly face the challenge of producing a clean print without flooding (foil fill-in). The following suggestions could help solve this re-occurring problem.

Make-Ready
The correct make-ready preparation is a key step to your foil success. When stamping small type or an intricate design, hard make-ready board like epoxy glass board or phenolic board seems to work best. The result will be a crisp stamp without punch on the back side of the sheet.

Proper Foil
Make certain that you are using the proper foil. Foil is manufactured with different releases and adhesives for particular paper stock and applications. Working closely with your foil supplier will assure that you will find the best foil for fine-line stamping. Source-FSEA

Test It Out!
When stamping your foil to the substrates, make sure your foil adheres and bonds well. Here's a simple test for adhesion: Put medium tack masking tape over the imprinted area, remove with a rapid jerking motion. If no pigment is visible on the tape, you have a good strong transfer and bond. Another test would be to moisten a cloth with rubbing alcohol, wipe the area back and forth at least five times without removing any pigment.

Solid Panel Tips

Smudge-Proofing
Often jobs may require stamping a solid panel of white foil on a dark background, e.g. duplex. Problems can arise if customers type on the white foil panel. Invariably, no matter what foil is used the typed letters will smudge or rub off. To overcome this, use a fine screened die for a white panel. This gives the same appearance as a solid panel and the smudging is eliminated. ' Source FSEA

Trapped Gas
When foil stamping, gas can build up between the foil and the paper. If your image has many solid areas, the gas can get trapped and cause bubbles. To avoid this, we can use a fine screen that will not be noticeable, but will allow the gases to escape. If you think your job might require this, you can us your file and we'll discuss your project.

Counter dies, also referred to as male dies, can be made from several materials: poured fiberglass, etched magnesium plates, embossing compound, or layered counterboard. Brass counter dies are poured fiberglass.

Poured Fiberglass
If holding as much artwork detail as possible is imperative to your job, poured fiberglass counters are the ones to use. The material used for poured fiberglass counters is extremely hard, specifically designed for crisp, clean stamping applications and for long-running jobs.

Magnesium Counter Dies
To ensure a crisply detailed raised image, it is important to etch the female die enough to accommodate a male counter die yet also leave spare room for the weight of the paper. The counter die is etched several thousandths of an inch deeper than the female die. When embossing, this allows the counter die to bottom-out without disturbing the texture of the surrounding paper. See the paper stock selection guide for embossing for additional details.

OWOSSO customers are reporting great results and increased simplicity of make-ready using poured fiberglass and magnesium etched counters for both cold and hot embossing.

Embossing Compound
If your image has a lot of extremely fine detail, your best bet might be to produce your own counter die on your press.

Pressed into Layered Counterboard
Layered counterboard is a material that can be found from sources that carry engravers materials. It is a board made up of several layers ' 36 or more. This is another method of creating your own counter die on your press.

Several important factors combine to determine the choice between brass, magnesium and copper for creating the best results with your embossing and debossing dies. No single factor should be used alone to make the decision. Since all of the factors listed below interact with one another, their cumulative effect should be considered. Experience will help you make the best material choice, and your printer, press operator, and photoengraver can all provide valuable assistance.

Choosing magnesium, when appropriate, can yield cost savings for your customer and speed up turn-around, without sacrificing quality. Brass dies are hand sculpted and machined therefore making them the most expensive of the three metal choices. Brass dies are the most durable and since they can be repaired, the life of the die is almost endless. Interpretation of the artwork is only possible with brass dies, including shapes, textures and edges.

Copper is a relatively harder metal used for the same applications as magnesium dies. If your job requires a more durable metal, copper is the best selection. Please consider the following:

• Surface Area Pressure
• Artwork Designs
• Length of Press Run
• Substrates
• Handling and Maintenance
• Experienced Craftsmanship

Surface Area Pressure
The amount of pressure required to achieve the best results depends on the size of the surface area being embossed or debossed. Equal embossing and debossing results for a one-inch square surface area require less pressure than that needed for five square inches. Depending on the other factors involved, magnesium is best used on smaller areas with smoother papers while copper is beneficial for larger areas and more heavily textured papers, and extremely long runs. Brass is generally used for combination foil and embossing dies.

Artwork Designs
Durability of your embossing and debossing dies under pressure should suit your artwork design. Relatively more pressure is needed for the best results in bold and uniformly spaced designs. For example, a solid square requires more pressure than an outlined square of the same size. Fine detail and unevenly distributed artwork designs require relatively less pressure and can be readily achieved with magnesium. However, bold and evenly spaced artwork to be printed in long runs may require pressure that copper can withstand best.

Length of Press Run
Generally longer press runs can cause erosion on embossing and debossing dies. For this reason, copper dies are recommended for long runs. However, this is a relative guideline since many factors determine what is even considered a long run. For example, heat is a factor that can reduce the durability of metal. Magnesium has achieved runs in the upper tens of thousands. If you are using high heat and have a long run with your embossing and debossing, brass or copper might be better choices.

Substrates
Is your paper stock recycled, heavily textured, coated, or uncoated? Generally, the tougher the paper stock, the more durable the metal for your die should be. Smoother paper stocks don't wear as much on your embossing and debossing dies, and magnesium can yield excellent results. Copper dies may be worth the extra cost when using heavily textured papers and for longer runs.

Handling and Maintenance
Press tolerances should be checked periodically. When adjusted accordingly, you can considerably increase the life of your embossing and debossing dies. Also, be careful in make-ready. Scratching and dents can be avoided with just a little attention. With proper handling in all these areas, you will get more from your die. A good way to store your magnesium dies, is to first coat them with a little cooking spray or oil such as Pam'. When stored and handled properly you may find you are using magnesium again and again.

You'll offer your customers the best cost, speed, and quality, when you balance all of the above factors. Paper houses have sample departments ' use them to test your dies on different stock. Artwork designers should also consult with their printers and finishers concerning stock choices and designs. When printers and finishers know ahead of time what they will be working with, it is much easier for them to evaluate the best metal for your embossing and debossing job.

OWOSSO welcomes any technical questions or inquiries. Just your job specifics including artwork design, length of run, paper stock, and temperature and we can help!

Experienced Craftsmanship
Since , OWOSSO continues to set the industry standard for both craftsmanship and service. Our experienced staff has a thorough knowledge of the substrates, the die-making process, and the best production techniques that produce the highest quality dies.

For more Aerospace Machined Partsinformation, please contact us. We will provide professional answers.