For over 60 years, Verdugo Tool & Engineering has cultivated world-class wire EDM, laser cutting, tool and die design, CNC machining, and stamping expertise to provide customers with high-quality, accurate tooling. As a job shop with many years of generational experience and using our state-of-the-art CAD modeling, we can design and manufacture custom-engineered tool and die implements, such as jigs, fixtures, dies, molds, machine tools, cutting tools, and gauges.
After designing and manufacturing the tool and die hardware that fits your production needs, our job shop can get right to work manufacturing your components on our high-production machines to deliver your bespoke parts on time and with no need for secondary processing. With custom tool and die design, we remove the engineering burden from our customers to streamline the manufacturing process.
- The Tool and Die Design Process
Our process begins with a part or blueprint delivered to us by the customer that needs to be created. From there, we reverse engineer the part’s design using our state-of-the-art modeling capabilities and Solidworks software. We create blueprints for simple or complex tool and die fixtures, which can be made up of hundreds of components and can perform multiple operations in a single press cycle. Once the tooling designs are created, we begin production on the components leveraging our years of experience.
When considering the components that make up the tooling, we must consider the tool steel properties. Various steel and steel alloys will provide different benefits depending on production needs. Dimensional stability, abrasion resistance, wear resistance, impact toughness and bend strength are all qualities to be considered when selecting a material. These include:
D2 Tool Steel – great for blanking dies, punches, and forms
A2 Tool Steel – highly versatile and ideal for holders, punches, and dies
M2 Tool Steel – excellent wear resistance and great for punches and dies
- Benefits of Die Design
Choosing Verdugo Tool & Engineering to custom engineer your components offers a range of benefits, with the most apparent being a more efficient manufacturing process. Some other benefits include:
Once we have an outline for the tool, we can simulate the strip on the CAD software. This will tell us what will be most efficient and where there could potentially be trouble spots in the tool and die design. Until the tool is verified as fully operational in the simulated production run, there will be no labor or material expenses incurred in the tool room. This ensures that once we build the tool it is immediately ready for production, streamlining the customer manufacturing process.
Tight Tolerances and Consistency
The hallmark of a good tool is the ability to produce consistent parts run after run regardless of the operator and the machine it is mounted in. We have extensive knowledge and experience of how to get this done. From the positioning and shape of the punches to the clearances of the dies we are able to precisely position all your parts features so that they fall within specifications time and time again.
We can help engineer more efficient solutions for your troublesome parts. Whether you have increased demand and are looking for a more efficient manufacturing process or have old-fashioned dies that are either broken or hard to work with, we have extensive experience working with clients existing tooling. With over five decades of experience, we can advise whether you need new tooling or if we can help improve upon your existing tooling with additional fixtures, jigging, or new or repaired components—getting you back into production faster than ever before.
- Tool Design Applications
We can engineer anything your company needs to be used in a wide range of applications. A few examples of types of tooling we are experienced with include but are not limited to:
- Multi-out progressive dies
- Short-run tools
- Secondary tools
- Precision gauges and fixtures
- CNC and drill fixtures
- PEM and press brake tools
- Machine automation tools
- Quality control tooling
Custom Parts From Verdugo Tool
From the engineering and manufacturing phases to the finishing and quality control phases, we ensure that our clients receive high-quality, accurate parts on time and on budget. Our over 50 years of knowledge and experience make this process more efficient and convenient for you. We are committed to quality and offer quality assurance for your parts or product through our ISO-9001:2015-certified Quality Management System.
Manufacturing relies on high-quality tooling to cut, stamp, and form various materials into precision parts. Highly refined tool and die designs can ensure customer satisfaction by maximizing run rates and minimizing downtime. Since 1957, Verdugo Tool & Engineering has built a name for itself on 3D tool and die design. Learn more about the process and how our customization capabilities can support your business.
- What Is Tool & Die Design?
Creating customer-specified parts requires tooling. Manufacturing precision parts to maximize profit for our clients requires a carefully thought-out sequence of punching, cutting, and forming to reduce labor and scrap. This requires a well-mapped out tool design that not only consistently makes precision parts, but also considers ease of use and safety for our operators. It is the experience we have in collaboration with our highly skilled operators that sets us apart from other stamping houses.
At Verdugo Tool we employ only the highest skilled die makers with more than 30 years of experience. Our die makers are extremely skilled with manual lathes, grinders, and mills as well as trained on cutting-edge CNC and EDM machines. This allows us to quickly repair tools, troubleshoot new and existing tooling, as well as make prototype tooling extremely quickly with little to no need for engineering input—saving our clients time and money.
- Die Design Importance
Tool and die design plays a critical role in the structure and quality of end products—it is at the heart of any new build. As a result, manufacturers must exercise great care when making design considerations. We at Verdugo Tool & Engineering utilize both AutoCAD and SolidWorks to design custom solutions for our clients. We prepare dies to our client’s specifications while eliminating any performance concerns that may later cause malfunctions.
The design process offers a chance to create complete drawings and analyze the different operations to identify any issues that might negatively impact the rate of production. It ensures that the tool is machine-ready, saving on future repair costs and downtime. The tool and die design stage involves analyzing the arrangement of every hole, bend, and punch in a strip. CAD software helps engineers design the blank strip and determine key characteristics like feed direction, tolerances, and scrap minimization.
Tool production, which includes detailing all components, ordering tool materials, and machining die blocks, can start as soon as the customer approves the design. This is where working with a tool and die designer like Verdugo Tool & Engineering is useful. Our tool makers and engineers help prevent delays and quality issues while adding value that supports long and robust part life. Also, we offer prototyping services to ensure high-performance designs with the expected functionality.
- Benefits of Engineering
In depth tool and die design and analysis allow you to optimize your manufacturing operations to enable:
- Fast and easy setup. It takes less time to set up tooling when clamping and clamping and fixturing is considered. We incorporate single-minute rapid die changeovers and inserts with quick sharpening capabilities into each die’s design for cost-effective production. Our proprietary system for swapping out tooling plates to quickly align dies is critical for reducing downtime and saving on labor.
- Higher versatility for part geometries. Manufacturers can easily create families of parts with similar but different geometries using sheet metal stamping processes. With a custom-designed die with proprietary inserts we can produce multiple parts using the same base tooling saving you time and money.
- Increased production speed. Our tools are designed to produce more parts in a shorter period of time, with low cycle times per part in high-volume production runs. We also design our punch and die tooling for easy maintenance to reduce downtime, with die protection sensors included to monitor tonnage, misfeeding, buckling, end-of-stock, and part ejection allowing us to run unattended for hours at a time.
- Reduced waste. Using our 3D CAD programs we are able to manipulate and rotate parts to minimize the scrap. This allows us to reduce the amount of material we purchase as well as reduce the amount of scrap we generate, passing the savings onto our clients.
- Superior repeatability. Carefully designed tools will take advantage of the location of holes and bends to minimize the movement of material during production. Limiting the flow of material reduces stress on the part and will result in less breakage and higher repeatability. This means that you can be sure that all of the parts we run will be precise and consistent as well as need less maintenance.
Tool & Die Design at Verdugo Tool
Our in-house, state-of-art equipment and experienced tool makers and engineers can help you design tooling for manufacturing superior products. With a commitment to quality, we maintain ISO 9001:2015 and ITAR certifications to exceed customer expectations. Contact us today to learn more about our tool and die design services or to request a quote for turnkey solutions.
Progressive dies are stamping tools that produce a part sequentially in several stages as the material moves through it. They usually begin with blanking or cutting operations that trim the material to the shape of the part. Further down the tool the parts are formed and then cut off and released into a bin. This is in contrast to short run tooling which requires an operator to manually move the part one at a time through each operation. This means that progressive dies are the primary choice for efficiently producing parts in large volumes.
Since 1957, Verdugo Tool & Engineering has developed a reputation for quality progressive tooling. Our facility contains a dedicated tool room and production department for the design and manufacture of custom progressive tooling, including progressive dies that routinely hold +/- .003 on edges and +/- .001 or less on holes. Learn more about progressive dies, how we use them in our stamping procedures, and how progressive die stamping can benefit your business through speed and accuracy.
- What Are Progressive Dies?
Progressive die is a blanket term for a class of stamping tools that produces parts progressively through a sequence of cutting, piercing, and forming operations. The strip of material feeds through a series of stations that each perform a specific operation to produce a completed part. Because there are many operations being performed in one tool, progressive dies are often highly complex and require many years of expertise to design, manufacture, and maintain.
Since progressive dies are so complex and their production demands are so great, they are generally manufactured to extremely tight tolerances. This ensures that material runs efficiently through the tool and that all parts are identical to within .001 of an inch. Because of their accuracy and repeatability, progressive dies are used to manufacture parts in a variety of industries including aerospace, defense, electronics, automotive, and more.
- Progressive Die Stamping
Progressive dies can be used to manufacture all kinds of parts ranging from large to small or simple to complex. With intricate cam and spring systems parts can be manipulated to be folded well past 90 degree angles and they can be punched and threaded from almost any direction. Using removable inserts and different cutout punches, progressive dies can be manufactured to produce multiple parts in the same tool. Along the same lines, they can be engineered to produce multiples of the same part in just one press cycle.
These tools often run in a press at rates of over 1000 cycles per hour. Because of this, progressive dies are often used for projects where there will be a large volume of parts. Additionally they can be engineered with the use of electronic sensors to run without operator oversight enhancing their profitability. These tools are highly engineered and robust allowing our clients to save time and money in the long run via reduced piece prices and increased production rates.
- Benefits of Progressive Dies
Progressive die stamping is a versatile and cost-effective manufacturing process that offers several advantages over other sheet metal stamping methods. The most significant benefit of progressive die stamping is the ability to efficiently produce large quantities of complex parts with tight tolerances. Additionally progressive die stamping has other advantages as well:
- High run rates for large production projects
- High precision and repeatability
- Fast and easy setup
- Minimal material scrap
- Reduced price-per-unit labor costs
- Can produce multiple parts on the same tool
Progressive Die Solutions at Verdugo Tool & Engineering
As a third-generation toolmaker with over 50 years of experience in progressive die technology, Verdugo Tool & Engineering has the knowledge and expertise to help you take your business to the next level. In our commitment to quality and continuous innovation, we maintain ISO 9001:2015 and ITAR certifications and conduct thorough product inspections.
Our commitment to excellence is evidenced in our ability to offer customers free maintenance for the life of all tooling provided the die and production runs stays in house.
Our experienced team of engineers, press operators, and tool makers can design and build custom progressive dies for any application, and we strive to be your one-stop shop for all your tooling and metal stamping needs. Contact us for more information about our services, or request a quote today to begin your project.
Short-run tooling can give those looking for a prototype or smaller production run a faster and affordable alternative to progressive stamping. Depending on your needs we can develop custom solutions for your particular project. Let our years of experience guide you to maximum efficiency and profitability.
Whether you are interested in prototyping, small batch production, or fully automated manufacturing solutions, Verdugo Tool & Engineering has the expertise and resources to exceed your needs.
- What is Short-Run Tooling?
Also known as short-run stamping, short-run tooling is a manufacturing process used to produce small runs (usually less than 5,000 pieces) of uniform sheet metal parts. It usually consists of one operation per tool and requires an operator to manually load the parts or material into each station. This makes short-run tooling ideal for prototyping or highly irregular and complex forms. It is also the preferred method for deep draws and embosses.
Often called “quick and dirty” tooling, short-run tooling can be made quickly and cheaply with only a couple of hardened blocks or it can be made more robust to hold tight tolerances. At Verdugo Tool & Engineering we implement special proprietary lineup fixtures that help us set up each operation. Because of this we are able to pass on initial start up savings to the customer.
- Short-Run vs Progressive Tooling
When we first evaluate a customer’s new project it is important to determine how exactly to manufacture their parts so that they are satisfied with the startup costs, the piece price, and most importantly the lead times. In order to do this, it is important to understand the differences between short-run tooling and progressive tooling.
Generally speaking because of its increased complexity, progressive tooling has a higher initial cost than short-run tooling. Short-run tooling strives to be as quick and fast to startup as possible while progressive tooling takes more time to carefully engineer and build. For prototyping or small enough projects, we even offer the option to forgo purchasing tooling and incurring a small non-recurring engineering charge (NRE) instead.
Conversely, once finished progressive tooling is very efficient and fast to run (1000 pieces/hour or more) whereas short-run tooling can be a little more labor intensive (200-300 pieces/hour) leading to slightly higher piece prices. Because of these nuances, it is important we collaborate with our customers on the exact requirements and part forecasts for each project before we get started.
- Common Misconceptions
Even though the lead times are shorter than those of progressive dies, short-run tooling should not be considered a “quick and dirty” manufacturing method sufficient for all of a client’s manufacturing needs. Short-run tooling is still very precise, accurate, and repeatable over thousands of parts. Ultimately the project’s budget and part forecasts are the driving factors that determine which route to go.
Short-run tooling excels when the parts have very complicated forms or need to be rotated or turned around for various operations. These manipulations are very hard to do in a progressive die, but in a short-run tool, the operator can do all of these things manually making it much easier to get the desired result.
Short-run Tooling From Verdugo Tool & Engineering
For all your tooling needs, Verdugo Tool & Engineering has the experience and equipment to handle short-run or progressive tooling to fit your project. We can set up your tool using one of our proprietary lineup methods or we can engineer it to fit into your single die changeover systems as well. Additionally, we have standardized our shut heights and clamping methods to save you time and money.
With our state-of-the-art facility, we can easily leverage our expertise in laser cutting, wire EDM, and CNC machining to help save you time and money on all your tooling needs. With more than five decades of experience, we are confident we will exceed your expectations.
Contact us today to receive a no-obligation consultation regarding your next project.