Long-Stroke Multi-Stage Progressive Die Automatic Strip Feed Progressive Die Long Travel Follow on Stamping Tool for Sheet Metal Hardware Press Moulding

Long-Stroke Multi-Stage Progressive Die
Our custom long-stroke multi-stage progressive die is designed for complex sheet metal components that require multiple sequential bending, forming and piercing operations. Unlike short-stroke terminal dies that focus on high-speed blanking of small flat parts, this die features an extended die body with many forming stations arranged along the strip path. The metal coil advances pitch by pitch, and each station performs one dedicated operation — piercing, lancing, pre-bending, final bending, embossing, coining and blanking — until the fully formed 3D part is separated at the last station. This die is ideal for automotive brackets, electrical clips, connector housings, structural shields and other complex sheet metal hardware where multiple bends and formed features must be produced in a single automated run.

Extended Multi-Station Layout for Complex 3D Forming
The die body is engineered with an extended working area accommodating 8 to 30+ forming stations along the strip direction. This allows complex parts with multiple bends, offsets, embosses and pierced features to be fully formed in one continuous progression — eliminating the need for multiple single-operation dies, manual part handling and secondary bending operations. Each bend can be split into pre-bend and final-bend stages for controlled, repeatable forming.

Sequential Multi-Stage Bending with Springback Compensation
Critical bends are distributed across multiple stations rather than formed in a single hit. Pre-bending, restriking and coining stations are strategically arranged to gradually bring the material to the target angle, with each stage applying incremental springback compensation. This staged approach significantly reduces springback variation, especially for high-strength steel, stainless steel and thick-gauge materials, delivering consistent bend angles across long production runs.

Long-Strip Stability & Anti-Warping Feed System
For long die bodies with many stations, strip stability is critical. We integrate precision pilot pin positioning at multiple intervals along the strip path, combined with strip lifters, pressure pads and guide rails to prevent strip lifting, twisting and warping during long-travel feeding. This ensures the material remains flat and accurately registered at every forming station, even after 15+ stations of progressive deformation.

Heavy-Duty Long Die Base with Multi-Point Guidance
The extended die set is built on a stress-relieved, precision-ground die base with multiple guide pillar sets distributed along the die length—not just at the corners. This multi-point guidance system maintains uniform parallelism across the entire long working area, preventing deflection and "banana effect" under high forming loads. The rigid construction ensures consistent cutting clearance and bend depth at every station, even under millions of cyclic hits.
Modular Forming Insert Design for Quick Changeover
Each bending and forming station uses independently replaceable modular inserts. When a particular bend needs adjustment due to material lot variation or design revision, only the affected station insert is modified or replaced—without disassembling the entire die. This modular approach drastically reduces tryout iteration time, simplifies maintenance and enables fast die modification for part design changes.

Integrated Scrap Management & Part Ejection
Long multi-stage dies generate scrap at multiple piercing stations. Custom internal scrap chutes route slugs to designated discharge points along the die body, preventing slug buildup and jamming. At the final blanking station, the finished 3D part is ejected via air blow or mechanical kicker onto a conveyor, ensuring smooth, uninterrupted automated production without manual part retrieval.

This multi-stage progressive forming die serves industries requiring complex, high-volume sheet metal components
Automotive—Seat brackets, door panel clips, hinge components, electrical connector housings, sensor mounting brackets, brake line clips, structural reinforcement plates.
New Energy—Battery module brackets, busbar support frames, cooling system clips, motor housing components, charging connector parts.
Electrical & Electronics—Relay frames, switch housings, terminal blocks, EMI shielding cans, PCB mounting clips, connector shells.
Telecom & Data Center—Server chassis brackets, cable management clips, heat sink mounting parts, rack hardware, shielding frames.
Home Appliances—Washer/drum brackets, compressor mounting plates, hinge components, control panel frames, motor support structures.
Industrial Automation—Sensor brackets, actuator clips, conveyor components, relay sockets, terminal strip housings.
Aerospace—Lightweight bracket preforms, clip fasteners, structural sheet metal components (AS9100 compatible).