The Core Process of Customizing Non-Standard Parts through

The Core Process of Customizing Non-Standard Parts through 

Stamping Customizing non-standard parts through stamping is a systematic project that requires strict adherence to standardized processes to ensure that each step accurately meets the requirements. Specifically, it can be divided into the following six stages: 

1. Requirements Communication and Analysis

   This is the starting point of customization and a crucial step in determining whether the final product meets expectations. The client must clearly specify the core parameters of the non-standard parts, including but not limited to: usage scenarios (e.g., automotive parts, electronic device accessories, medical device components), stress conditions (static load, dynamic impact, vibration frequency, etc.), environmental requirements (temperature range, humidity conditions, contact with corrosive media), dimensional accuracy (tolerance range for length, width, and thickness; whether precision-grade standards are required), and appearance standards (surface roughness; whether plating or coating treatment is required). Meanwhile, the client (stamping manufacturer) needs to proactively identify potential needs, such as: production volume of non-standard parts (single-piece trial production, small-batch production, or large-scale mass production; different batches correspond to different mold selections and process optimization directions), delivery cycle (whether there are urgent production needs, requiring a balance between efficiency and quality), and cost budget (helping the client find the optimal balance between performance and cost, avoiding over-design). Both parties need to communicate multiple times to form a written "Requirements Confirmation Letter," clearly defining all technical indicators and delivery requirements to avoid subsequent cognitive biases.

2. 2. Product Design and Process Planning

   Based on the "Requirements Confirmation Letter," the client's engineering team will carry out product design and process planning work. First, using CAD (Computer-Aided Design) software, they will draw two-dimensional drawings and three-dimensional models of the non-standard parts, annotating detailed dimensions, tolerances, material types, and other information, and conduct a preliminary structural rationality analysis, such as: whether there are easily broken weak parts, and whether it is convenient for subsequent stamping processing (e.g., avoiding overly complex internal angles, reducing the difficulty of deep drawing processes). Subsequently, the stamping process route is formulated based on the product design scheme. The core contents include: Material selection: Selecting suitable metal materials according to requirements, such as ordinary carbon steel (Q235), stainless steel (304, 316), aluminum alloy (6061), etc., considering the material's strength, ductility, corrosion resistance, and cost; Stamping process design: Determining the required stamping processes, such as blanking (obtaining preliminary blanks), punching (processing holes), bending (shaping specific angles), stretching (creating three-dimensional shapes), and forming (improving dimensional accuracy), clarifying the sequence of each process; Die design: Designing dedicated stamping dies according to the process route, including punches, dies, unloading devices, positioning devices, etc., ensuring that the die accuracy matches the product accuracy, while also considering the die's service life and ease of maintenance.

3. 3. Die Manufacturing and Trial Molding

   The die is the core tool for customizing non-standard parts in the stamping process, and its quality directly determines the product quality. Mold manufacturing must strictly adhere to the design drawings, employing high-precision machining equipment (such as CNC milling machines, EDM machines, and wire cutting machines) to ensure the dimensional accuracy and surface finish of mold parts. Tolerances in critical areas must be controlled within the range of 0.005-0.01mm. After mold manufacturing is completed, a trial molding process is required: the mold is installed on stamping equipment, and a small batch of trial stamping is conducted using the same materials as actual production. The purpose of the trial molding is to check for any problems with the mold, such as: whether the product has burrs, cracks, or deformation; whether the dimensions meet the design requirements; and whether there are any issues with material jamming or improper unloading. If problems are found, the mold must be adjusted and repaired promptly until the samples produced from the trial molding fully meet the standards of the "Requirements Confirmation Form." Only then can the mold be put into formal production.

4. 4. Formal Production and Quality Control

   After the trial molding is successful, the formal production stage begins. The client needs to select appropriate stamping equipment (such as open-type, closed-type, or CNC stamping machines) based on the production volume and develop standardized production operation instructions, clearly defining the operating specifications and parameter settings for each process (such as stamping pressure, stamping speed, and die temperature). During production, a full-process quality monitoring system must be established, with specific measures including: First-piece inspection: Before each shift, the first product undergoes a comprehensive inspection (dimensions, appearance, performance), and production can only continue after it passes inspection; In-process inspection: Quality inspectors conduct sampling inspections of products at a prescribed frequency (such as 10-20 pieces per hour) to promptly detect any abnormal fluctuations in the production process; Final inspection: After all products are produced, 100% visual inspection and sampling performance testing (such as hardness testing, tensile strength testing, and corrosion resistance testing) are conducted to ensure that unqualified products do not flow into the next process or are delivered to the client.

5. 5. Post-processing and Surface Finishing

   Some non-standard parts require post-processing or surface finishing due to usage requirements. Common processes include: Deburring: Removing burrs generated during stamping through manual grinding, mechanical polishing, chemical deburring, etc., to avoid affecting product assembly and safe use; Surface Treatment: Depending on requirements, galvanizing (to improve corrosion resistance), chrome plating (to enhance wear resistance and aesthetics), painting (to protect the surface and achieve specific colors), passivation (to improve the corrosion resistance of stainless steel), etc.; Heat Treatment: For non-standard parts requiring increased strength or hardness, quenching, tempering, annealing, and other heat treatment processes are performed to optimize the mechanical properties of the material. After post-processing, a quality inspection must be conducted again to ensure that the surface quality and performance meet the requirements.

6. 6. Delivery and After-sales Service

   After the product passes inspection, the customer must deliver the non-standard parts to the customer on time according to the packaging method agreed upon by both parties (such as cardboard boxes, wooden boxes, pallet packaging to prevent damage during transportation) and delivery method (such as logistics transportation, door-to-door delivery). Simultaneously, complete technical documentation must be provided, including product drawings, material certificates, quality inspection reports, and user manuals. Furthermore, the customer must provide comprehensive after-sales support: if quality issues arise during product use (excluding human-caused damage), a timely response and solution (such as repair or replacement) are required; if the customer subsequently requires batch adjustments or design optimizations, technical support must be provided to ensure that non-standard parts continuously meet production needs.