Stamping Parts with Composite Processes

Stamping parts with composite processes combine stamping with other manufacturing technologies (e.g., welding, riveting, injection molding) to create integrated, multi-functional components, reducing assembly steps and improving structural integrity for industries like automotive and consumer electronics. Traditional stamping produces single-material, single-feature parts that require multiple post-assembly steps (e.g., welding two stamped brackets), increasing labor costs and the risk of assembly errors. Composite processes eliminate these issues by integrating features during production.

Common composite processes include stamping-welding (stamping two parts, then spot-welding them in a single line), stamping-injection molding (overmolding plastic onto a stamped metal part), and stamping-riveting (forming rivets during stamping to join layers of material). For example, an automotive door panel reinforcement uses a stamping-welding composite process: two steel sheets are stamped into half-shapes, then robotically spot-welded along the edges during the same production cycle, reducing assembly time by 30%. Stamping-injection molding is used for consumer electronics— a stamped aluminum frame for a laptop is overmolded with plastic bosses to attach screws, eliminating the need to glue or fasten separate plastic parts.

Composite processes also enhance part performance: combining metal stamping with plastic injection molding creates parts with both metal’s strength and plastic’s insulation properties—ideal for electrical enclosures. Additionally, composite processes reduce material waste: a stamping-riveting process for multi-layered heat sinks uses less material than assembling separate stamped layers with screws. A automotive supplier reported that composite stamping parts for chassis components reduced weight by 15% (via material optimization) and assembly costs by 25% compared to traditional multi-part assemblies. For complex, multi-functional components, composite stamping processes deliver efficiency, performance, and cost savings.

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