Automation Dies Manufacturers in India
Engineered for high-volumne manufacturing maximum plant safety, and ±0.1mm precision built locally in Rajkot for global standards
5 Things That Make an Automation Die Different
Gripper Clearance Pockets
Manual dies have flat, uninterrupted surfaces around the die cavity. When you mount a servo transfer system, the gripper fingers physically collide with the die plate at cycle speed — damaging both the die and the transfer bars. Automation dies have precision-machined clearance pockets so grippers can enter and exit the die area without contact, even at 40 SPM.
Integrated Part Lifters
After the press stroke, the stamped part sits inside the die cavity. With manual operation, an operator pries it out using tongs. With automation, there are no tongs — the part must be lifted to a position where the transfer gripper can grab it. Automation dies have spring-loaded or pneumatic lifters built into the die shoe that push the part up on every stroke.
In-Die Proximity Sensors
In a manual setup, the operator looks to confirm the blank is placed correctly. On an automated line running at 20-40 SPM, there is no operator looking. Automation dies have inductive proximity sensors and optical fork sensors embedded at critical stations. These detect mis-feeds, double blanks, and stuck parts — triggering an automatic press stop before a crash.
Engineered Scrap Ejection
Manual dies let scrap slugs accumulate on the die surface. Operators sweep them off between cycles. On an automated line, there is nobody sweeping — and scrap buildup jams the transfer system. Automation dies have angled chutes and slug clearance holes machined into the die shoe so scrap falls away cleanly on every single stroke.
Optimized Die Open Height
With manual operation, the die open height is arbitrary — operators just need enough space to reach in with tongs. In automation, every millimeter of open height adds to the transfer arm travel distance, which directly limits your achievable SPM. Automation dies minimize the open height to reduce travel and maximize cycle speed.
Die Specifications by Type
| Parameter | Transfer Die | Progressive Die | Compound Die |
|---|---|---|---|
| Material | Tool steel, 58–62 HRC | Tool steel, 58–62 HRC | Tool steel, 58–62 HRC |
| Surface Finish | Ra 0.4 μm | Ra 0.4 μm | Ra 0.2 μm |
| Tolerance | ±0.01 mm | ±0.02 mm | ±0.005 mm |
| Max Sheet Thickness | 6 mm | 4 mm | 3 mm |
| Design Life | 10,00,000+ strokes | 10,00,000+ strokes | 10,00,000+ strokes |
| Press Tonnage | 80–600 Ton | 30–400 Ton | 30–200 Ton |
| Price Range | ₹5–25 Lakh | ₹3–15 Lakh | On quotation |
Die Types We Build
Transfer Dies
For parts that move between stations via servo transfer arms. Each station performs a different operation — piercing, bending, drawing, trimming. Parts can be rotated and flipped between stations.
- • Tolerance: ±0.01 mm
- • Sheet thickness: up to 6 mm
- • Gripper-clearing pockets included
Progressive Dies
Strip-fed multi-station dies where the part stays attached to the metal strip until the final cutoff station. Best for small, flat, high-volume parts.
- • Tolerance: ±0.02 mm
- • Sheet thickness: up to 4 mm
- • Design life: 10,00,000+ strokes
Compound Dies
Single-stroke dies that perform blanking and piercing in one press cycle. The tightest tolerances in our lineup — for precision parts where every micron matters.
- • Tolerance: ±0.005 mm
- • Sheet thickness: up to 3 mm
- • Surface finish: Ra 0.2 μm
Design-to-Delivery: 8–12 Weeks
Drawing Analysis + FEA Simulation
We analyze your part drawing, simulate formability, and identify thinning zones, springback angles, and wrinkling risks before cutting any steel.
3D CAD Design + Customer Approval
Full 3D die design with gripper clearance pockets, lifter positions, and sensor locations. You review and approve before machining begins.
CNC Machining + Wire-Cut EDM + Heat Treatment
Precision machining of die components, wire-cut EDM for complex profiles, and heat treatment to 58–62 HRC for wear resistance.
Assembly + Trial Run
Die assembly at our Rajkot plant. Full cycle testing on our presses integrated with our servo transfer systems at operating speed.
Shipping + On-Site Commissioning
Delivery to your plant, installation, final adjustments, and operator training. 12-month warranty begins at commissioning.
Single Vendor. Zero Integration Friction.
We build both the transfer system and the die set. Same engineering team. Same factory floor in Rajkot. When something needs adjusting — gripper clearance, lifter timing, sensor positioning — you call one number: (+91) 8295 150 210.
Compare that to buying dies from one vendor and automation from another. When grippers collide with the die surface, the die maker says the automation is wrong. The automation maker says the die clearances are wrong. You are stuck in the middle, your press line is down, and nobody is fixing it. With Ahlu Engineers, there is one team accountable for the entire system.
Industries and Parts
Automotive: Floor pans, door reinforcement pillars, engine mounting brackets, suspension arms, seat rail assemblies, oil pan housings, brake dust shields.
Appliances: Washing machine drums and outer tubs, AC outdoor unit panels, microwave oven casings, refrigerator compressor brackets, chimney panels.
Electrical: MCB enclosures, distribution board backplates, contactor body shells, panel board frames, switchgear cabinet components.
Frequently Asked Questions
Send Us Your Part Drawing
We will return a die feasibility study with tonnage recommendation, die type selection, and budgetary estimate within 48 hours.