A customer came to us with an existing stamping die set that had been in use for over 25 years and had undergone multiple modifications. The die was cracking every time it was used, causing repeated failures.
The customer had two key questions:
Why was the die breaking?
How could they get it back up and running?
As a full-service machine shop, our engineering team carefully measured and inspected the die, compiling a detailed report for the customer. The findings revealed that the pins and bushings were severely worn out, and the top half of the die was exerting excessive pressure on the bottom half, causing it to crack.
Due to the die’s age and extensive wear, the best long-term solution was a full replacement — ultimately more cost-effective than repairing select components.
The customer entrusted our machine shop to design two alternative cutting methods, with a report outlining the advantages and disadvantages of each.
Presenting the Solutions: One option kept a similar design to the original die but with updated materials and improved tolerances. The second was a more modernized approach optimizing efficiency and durability. The customer chose the design that best fit their production needs and budget.
To prevent the original issue from reoccurring, we made a key improvement by adding greaseable Zerk fittings to the bushings. This allowed for regular lubrication, reducing wear and extending the life of the new die.
Successful Implementation: the customer is now running reliable production with reduced downtime and improved confidence in their tooling. They continue to count on us for precision machining, problem-solving, and durable solutions that stand the test of time.
“We had been struggling with a stamping die that had been in service for over 25 years, constantly cracking and causing production delays. The team quickly diagnosed the issue, identifying worn-out bushings and misalignment as the root cause. They provided a detailed report outlining two die repair and replacement solutions, helping us make the best decision for our operation.”
“Not only did they design a more durable die, but they also added greaseable Zerk fittings to extend its lifespan and prevent future wear. Their expertise in tool and die services, precision machining, and stamping die repair saved us time and money in the long run. Our production is now running smoother than ever.”
Production Manager
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