Progressive die forming is an advanced metal working process which enables the production of complex components through a sequence of operations integrated into a single mould. Mainly used for sheet metal, this method combines efficiency, precision and versatility, making it ideal for high volume productions.

How does progressive moulding work?

The heart of this process is the use of a complex equipment consisting of a series of workstations arranged in linear succession. Each station is designed to perform a single specific operation – such as cutting, bending, punching or deep drawing – on a continuous sheet strip.

The cycle begins with a metal coil which is unwound and automatically fed into the press by a synchronized feeding system. The sheet moves step by step inside the mould, and each cycle of the press undergoes a partial transformation, each station contributes to the progressive realization of the final piece.

Thanks to this perfectly coordinated sequence, the sheet is continuously and precisely shaped until the desired component is obtained. At the end of the process, the finished part is separated from the remaining strip, ready for eventual assembly or finishing.

This method allows for high production efficiency, excellent repeatability of results and a significant reduction in waste and processing times.

5 distinguishing features of this type of moulding

1. Integrated and continuous process: this type of molding allows multiple operations – such as cutting, forming and finishing – to be performed within a single production cycle. This integrated approach dramatically reduces downtime between phases, thus increasing overall process efficiency.
2. High level of automation: the whole system is designed to operate with synchronized sheet feed and an automated sequence of operations, minimising human intervention. This ensures greater accuracy and consistency in the results.
3. Wide compatibility with materials: this type of molding is suitable for a wide range of metal materials, including steel, aluminum, copper and special alloys. Generally, the materials processed have thicknesses between 0.5 mm and 6 mm, offering application flexibility in different industrial sectors.
4. Fast and highly efficient production: thanks to the continuous and automated nature of the process, it is possible to produce hundreds of pieces per minute. This speed of production allows to optimize the times, significantly improving the productivity.
5. Optimisation of material use: The mould structure minimises waste, making the most of the sheet surface. Any waste is recovered and reintegrated into the production cycle, contributing to a more sustainable management of the resources used in the production cycle.

Progressive molding is a cost-effective solution for those who require high precision, speed and sustainability, thanks to the reduction of waste and the efficient use of resources.

Its adoption is particularly recommended for serial productions that require high quality standards and repeatable over time.

Contact us now to find out how this type of production can reduce development time and improve efficiency in your company.