How does automotive stamping work?

Automotive stamping is a key manufacturing process in the automotive industry which consists on transforming metal sheets into components with specific shapes.

It is a cold working deforming process using mechanic or hydraulic presses to cut, bend, and mold metals, generally steel and aluminum. This is an essential process to create structural pieces and car bodies which meet design and safety standards in modern vehicles.

Stamping is performed in several phases including die-cutting, drawing, folding, and forming. Through this process, chassis components, suspension parts, exhaust systems and car cabin parts are built. The resulting stamping parts are critical for car assembling due to their endurance, precision and lightness.

Phases of the car stamping process

The automotive stamping process consists on several steps which assure the proper transformation of metal according to design requirements.

Some of the phases include:

1. Blanking: a press is used to cut the metal sheet in the desired way. This stage assures the material’s right dimensions before going to the next steps.
2. Bending: the metal is deformed without getting broken to apply it a specific shape. Bending is essential to create the required angles and curves in parts.
3. Hemming: Deep hemming allows the creation of complex tridimensional shapes as tanks and car body components.
4. Deburring: after cut and molding, the parts experience a process of polishing edges and imperfections.
5. Finishing: the stamped piece may receive superficial treatments such as galvanizing or painting to improve its corrosion endurance and durability.

Innovation in automotive stamping

In later years, car stamping has witnessed important technological advances which have improved efficiency and accuracy in the process. Among these innovations: 

• Automation: the implementation of robots and automated systems in stamping plants have optimized production times and reduced human errors. Modern factories operate with automated production lines which integrate robots to feed presses and pick finished parts which reduces significantly time-out periods.

• Heat stamping: this advanced process allows molding steel parts at high temperatures to achieve a higher resistance. This is crucial for structural components requiring additional resistance without increasing dramatically the car weight.
• Digital simulation: By using advanced software, manufacturers can simulate the stamping process before carrying it out. This allows optimizing part design, prevent foreseeable failures and reduce waste of materials.

• Sustainability: the use of lighter and recyclable materials has gained relevance within the stamping industry. Aluminum, for example, has become one of the most used materials due to its lightness and high endurance which contributes to improve energy efficiency in vehicles and reduce CO2 emissions.

Sustainability and energy efficiency

In the current context where sustainability and carbon footprint reduction are a priority, automotive stamping has evolved to more sustainable practices. The use of light materials, such as aluminum, has allowed manufactures to reduce the whole car weight improving fuel consumption and reducing greenhouse emissions.

Also, the use of low-energy-consumption presses and adoption of recycling practices at stamping facilities have helped to reduce the process’ environmental impact. Recycling metal and material use optimization have been key for the industry to its transition towards more responsible practices.

Companies belonging to Autoparts From Spain with relevance in automotive stamping

Spain enjoys the presence of several well-known companies specialized in automotive stamping which belong to the initiative Autoparts from Spain promoted by SERNAUTO. These companies have integrated the most advanced technologies in their manufacturing processes which has allowed them to keep a relevant global position. Among the main companies devoted to automotive stamping are:

• Gestamp: this world-leading company in metal component manufacturing for cars, using heat and cold stamping to produce structural parts and chassis. Its focus on innovation and sustainability has consolidated its presence at international markets.
• Gonvarri industries: Gonvarri has integrated stamping solutions with a strong commitment towards sustainability. Its facilities are equipped with advanced technologies that allow manufacturing metal pieces with the highest efficiency and accuracy.
• Grupo Azpiaran: with more than 60 years in the sector, Grupo Azpiaran is specialized in producing high-precision components through metal stamping with a strong presence in the car and appliances industry.
• Sadaca: Sadaca stands out because of its great-scale production capacity and the implementation of innovative processes of automotive stamping. Its focus on quality and efficiency made the company a reference in the manufacturing of metal components for automotion.

Future of automotive stamping

The future of automotive stamping is linked to the development of more efficient and sustainable vehicles. While the industry moves forward to electrification, the need for lighter and more resistant parts will increase. The use of technologies such as heat stamping, 3-D printing and the components in materials assure a revolution in the process of automotive component manufacturing.

Furthermore, integrating Smart technologies such as artificial intelligence and IoT will allow companies to optimize their stamping processes then reducing costs and improving product quality.

Automotive stamping is an essential process for car manufacturing and Spanish companies have displayed their vanguard position regarding innovation, sustainability and efficiency. Thanks to technological advances and their capacity to get adapted to new market needs, these companies keep up with being key players in the global industry of cars.