What Are Progressive Dies?

    Progressive Dies is a fast and efficient way to make metal parts. In this process, a long strip of metal is fed from a coil into a tool called a progressive die. The metal moves through a series of stations inside the die. At each station, a different operation is performed-like cutting, bending, or shaping.

    By the time the metal strip reaches the end, a finished part is produced, and the leftover strip is removed as scrap. This process enables cost-efficient manufacturing through sequential operations, all within a single press stroke.

    Progressive Die Process

    Progressive Dies in Action

    Watch how our progressive dies work in real-time manufacturing environments, demonstrating the precision and efficiency of our tooling solutions.

    Types of Progressive Dies We Manufacture

    We design and manufacture a wide variety of progressive dies tailored to diverse part geometries and production volumes:

    1

    Single-Row Progressive Dies

    Ideal for medium to high-volume production with streamlined linear tooling.

    Single-Row Progressive Dies

    2

    Multi-Row Progressive Dies

    Suited for producing multiple identical or mirrored components in one operation, doubling productivity.

    Multi-Row Progressive Dies

    3

    Compound Progressive Dies

    An integrated solution that combines cutting and forming within the same stationโ€”used where extreme precision and repeatability are required.

    Compound Progressive Dies

    Why Choose Progressive Dies?

    Progressive dies are ideal for producing:

    High-volume production runs with consistent quality and minimal operator intervention

    Complex multi-operation parts requiring cutting, bending, forming, and piercing in sequence

    Cost-effective manufacturing through reduced setup times and automated material handling

    Key Features of Progressive Dies

    Multi-Station Design

    Progressive dies are typically composed of multiple stations arranged sequentially along the path of the metal strip.

    Sequential Operations

    Each station performs a specific operation, such as cutting, bending, or forming, until the final part is produced.

    High Production Rates

    Progressive dies are ideal for high-volume production due to their ability to perform multiple operations in a single stroke.

    Cost-Effectiveness

    By reducing the need for multiple tooling setups, progressive dies can be more cost-effective than other stamping methods.

    Automation Integration

    Progressive dies are often designed for integration with automated systems, further increasing production speed and efficiency.

    Where Ahlu Engineers Adds Value

    At Ahlu Engineers, we specialize in designing and building precision-engineered progressive dies tailored to your application. Our in-house expertise allows us to:

    Optimize strip layout and station sequencing for maximum material utilization

    Design pilot and carrier systems for precise part progression

    Engineer dies for high-speed production with minimal maintenance requirements

    Provide comprehensive die validation and production optimization support

    Ahlu Engineers Progressive Die DesignAhlu Engineers Progressive Die Design

    Industries We Serve

    ๐Ÿš—

    Automotive

    (Chassis, Brackets, Seat Structures)

    ๐Ÿ”Œ

    Electronics

    (Terminals, Connectors, EMI Shielding)

    โœˆ๏ธ

    Aerospace

    (Brackets, Fasteners, Lightweight Components)

    ๐Ÿ 

    Appliances

    (Sheet Metal Parts, Enclosures)

    Ready to Increase Your Production?

    At Ahlu Engineers, we don't just build tools we engineer solutions that transform your manufacturing process into a high-efficiency, cost-effective operation. Contact us today for custom progressive die development, material optimization consultation, or complete tooling design services.

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