Choosing between progressive and single dies? Your decision affects costs, lead times, and production efficiency. Get it right with 30 years of stamping experience.
Progressive dies slash per-unit costs for orders above 100k units through automated feeding. Single dies save 40-60% on initial tooling for small batches under 10k pieces.
Let's analyze three critical factors that determine which die type suits your project. Discover how we've helped 300+ clients maximize efficiency.
1. How Many Parts Do You Need Annually?
Order volume dictates whether progressive dies justify their higher upfront cost.
Progressive dies become cost-effective at 50k+ units/year. For orders below 15k, single dies reduce tooling investment by 62% on average.
Cost-Per-Unit Comparison
| Annual Quantity | Progressive Die | Single Die | Break-Even Point |
|---|---|---|---|
| 5,000 | $1.80 | $0.95 | 7,800 units |
| 20,000 | $0.90 | $1.10 | 15,000 units |
| 100,000 | $0.48 | $1.05 | 22,500 units |
Client Example:
An EV battery manufacturer required 500k copper terminals annually. We implemented progressive dies that:
- Reduced production time by 40%
- Cut material waste to 2.8%
- Delivered parts at ¥0.12/unit vs original ¥0.29
Key Considerations: - Progressive dies require minimum 3-year production commitment
- Single dies allow modifications at 30% lower cost
2. What's Your Part Complexity Level?
Complex geometries influence tooling design and maintenance costs.
Progressive dies1 handle ≤4 bending stages2 effectively. For parts exceeding 6 features or requiring post-processing, single dies3 provide better precision.
Design Compatibility Matrix
| Feature | Progressive Die | Single Die |
|---|---|---|
| Wall thickness | 0.5-3mm optimal | 0.3-6mm |
| Bend radius | ≥1.5x material thickness | Any radius |
| Surface finish | Ra 3.2-6.3 μm | Ra 1.6-12.5 μm |
| Tightest tolerance | ±0.08mm | ±0.05mm |
Real Case:
A smart lock producer needed hinges with 5 different bending angles. We used modular single dies that:
- Achieved 0.03mm consistency
- Enabled 15% faster assembly
- Reduced scrapped parts by 85%
Critical Notes: - Progressive dies require 20-25% more maintenance hours
- Complex parts often need secondary operations with single dies
3. How Fast Do You Need Parts?
Project timelines dramatically affect die selection.
Single dies deliver first samples in 10-12 days vs 18-25 days for progressive tools. But progressive dies1 produce 800-1,200 pcs/hour once running.
Time Comparison Breakdown
| Phase | Progressive Die | Single Die |
|---|---|---|
| Tool design | 120-140 hours | 40-60 hours |
| Material procurement | 7-10 days | 3-5 days |
| Sample approval | 2-4 iterations | 1-2 iterations |
| Full production rate | 4500 pcs/shift | 900 pcs/shift |
Emergency Case:
A kitchen appliance maker suddenly needed 80k brackets in 30 days. We deployed 4 single-die presses in parallel. They received:
- First 5k units in 9 days
- Full order completion in 28 days
- 0 defects in final inspection
Strategic Insights: - Progressive dies need 3-4 weeks die "seasoning"
- Single dies allow concurrent production on multiple machines
Conclusion
Choose progressive dies for high-volume simple parts requiring low costs. Opt for [single dies
(https://arxiv.org/html/2402.12921v1)[^2] when handling complex geometries or smaller batches. We help you decide based on your specific needs.
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Explore the benefits of progressive dies for efficient tooling and cost management in complex geometries. ↩ ↩
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Understand the role of bending stages in die design and how they affect production efficiency. ↩
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Learn how single dies enhance precision and reduce scrap rates, especially for complex parts. ↩
