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Copper Alloy Progressive Die Parts With DFM Analysis To Shorten Tooling Lead Time
| Place of Origin | Shenzhen, China |
|---|---|
| Brand Name | TF |
| Certification | lSO9001 |
| Model Number | TF-002 |
| Minimum Order Quantity | 1 |
| Price | 0.10-0.30USD |
| Packaging Details | Carton packaging 18*15*12cm (packaging can be customized according to customer product requirements) |
| Delivery Time | 3days/Start |
| Payment Terms | T/T |
| Supply Ability | 10000000pieces/per month |
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xProduct Details
| Product Type | Progressive Die Stamping Parts | Main Material | Copper Alloy / Aluminum |
|---|---|---|---|
| Material Thickness | 0.2-2.0mm | Process Type | Blanking / Bending / Welding (Integrated) |
| Application Industry | New Energy / Home Appliances / Lighting | Surface Finish | Tin Plating / Powder Coating / Passivation |
| Tolerance Grade | Precision (±0.05mm) | Certification | ROHS / REACH / UL |
| Highlight | Copper Alloy progressive die parts,DFM Analysis progressive die parts,DFM Analysis progressive die process |
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Product Description
Progressive Die Solution from Design to Mass Production, with DFM Analysis to Shorten Tooling Lead Time
1．Progressive Die Stamping Quick Detail
We offer innovative integrated solutions for progressive die stamping and in-line welding. For components that require combining multiple stamped parts, we can integrate resistance welding, laser welding, or ultrasonic welding units at the end of the progressive die production line, achieving a seamless connection between stamping and welding. This integrated production method eliminates the flow of components between multiple suppliers, significantly shortens the overall manufacturing cycle, and ensures a high degree of consistency in welding position and quality, making it particularly suitable for products such as new energy battery connection components and home appliance motor terminals.
2. Progressive Die Stamping Product Description
In many electrical applications, individual stamped parts need to be reliably electrically connected to other stamped parts or wires. The traditional approach is to stamp them separately and then weld them individually, resulting in low efficiency and poor consistency. Our continuous die welding integration line tightly integrates these two key processes. For example, we can continuously produce battery connectors and precisely weld them to nickel sheets or wires on the same production line; we can also produce motor commutator segments and weld them online. This not only improves efficiency but also ensures the reliability of the connection for each component through precise positioning and stable welding parameters.
3． Progressive Die Stamping Product Features & Advantage
|
Stamping-Welding One-Stop Production |
Complete all processes from roll material to finished assembly within a highly automated system, reducing intermediate inventory, handling, and quality control points, and simplifying your supply chain.inventory, handling, and quality management points, simplifying your supply chain. |
|
Highly Controllable Welding Position & Quality |
Welding is performed by precisely positioning the stamped parts on the strip, with extremely high position repeatability; welding parameters are precisely controlled by the system to ensure consistent quality at each weld point. |
|
Significantly Improve Production Efficiency & Consistency |
The fast production cycle avoids the fluctuations of manual welding, making it particularly suitable for the large-scale production of components with high requirements for both welding quality and output. |
|
Reduce Overall Production Cost |
Save costs on space, labor, logistics, and multiple inspections through integrated production, giving assemblies better overall cost competitiveness. |
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Flexible Welding Process Adaptation |
Configure the most suitable welding technology (resistance, laser, etc.) based on material, thickness, and product requirements, achieving optimal welding results. |
4．Progressive Die Stamping Product Specification
|
Specification Item |
Detail / Range |
Note |
|
Integrated Welding Type |
Resistance Welding (Projection/Spot), Laser Welding, Ultrasonic Welding |
Selected based on product design |
|
Welding Position Accuracy (Relative) |
±0.1 mm (Typical) |
Based on die positioning accuracy |
|
Welding Strength Test |
Meet customer standards for shear force, tensile force, etc. |
Provide destructive test samples |
|
Applicable Material Combinations |
Cu-Cu, Cu-Ni, Steel-Cu, Al-Al, etc. |
Common electrical connection combinations |
|
Maximum Assembly Size (Per Cycle) |
Limited by die and welding station |
Usually suitable for small to medium-sized assemblies |
|
In-Line Inspection Capability |
Can integrate post-weld electrical test, vision inspection |
Real-time monitoring of welding quality |
|
Production Batch Suitability |
Suitable for medium to large volume orders |
Significant advantages after integrated line debugging |
5. Progressive Die Stamping Product Application
Our integrated stamping and welding components provide reliable electrical connections: Power battery modules and packs | Online welding of series/parallel connection plates (busbars) to nickel strips between cells, and welding of sampling line terminals, requiring low resistance and high reliability.
White goods motors and electronic controls | Welding of stator terminals for washing machine motors, terminal assemblies for air conditioner compressors, and commutator welding for motors; high demand, requiring consistent conductivity.
Lighting and power supply products | Welding of aluminum substrates to wires for LED modules, and welding of pins to copper sheets for switching power supply transformers, enabling automated and efficient production.
Industrial electrical connections | Welding of internal connection bars for circuit breakers, contactor contact assemblies, and high-current terminals, ensuring current carrying capacity and mechanical strength.
6. Frequently Asked Questions (FAQ)
Q: Can you handle complex custom designs and provide design optimization suggestions
A: Absolutely. This is our core expertise. We provide free DFM analysis within 3-5 days, often helping clients achieve 15-30% cost reduction through design for manufacturability.
Q: How do you ensure quality consistency and handle defect issues?
A: We implement a rigorous 4-stage QC system with 100% full inspection. Our track record shows 99.99% qualification rate.
Q: What are your lead times and how do you handle urgent orders?
A: Standard lead times: 3-7 days for prototypes, 7-15 days for mass production. We offer VIP prioritization cutting lead times by up to 30%.
Q: Will I get timely responses and professional support throughout the project?
A: Yes. You get a 1v1 exclusive consultant with 1-hour initial response commitment and 24-hour technical support.
Q: Can you provide material certifications and environmental compliance reports?
A: Yes. We provide material certifications and environmental test reports (RoHS, REACH compliant) upon request.
Q: How do you protect my designs and intellectual property?
A: We start with mutual NDA and implement strict mold ownership protection and confidential data security measures.
Q: What are your payment terms and MOQ requirements?
A: We offer flexible payment terms (T/T, L/C at sight) and MOQ from 1 piece for prototyping.
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