The aPriori Sheet Metal models support the following broad types of hard-tooled routings:

These types of routings differ from one another with the regard to the following important factors (among others):

The following table specifies these factors for each routing type:

Stage Tooling uses multiple presses (each with a single die) and manual transfer between presses. Each press performs a single operation on each part, in a defined sequence. The die sequence is typically comprised of some combination of a blanking die, forming die, cut-off die, piercing die, coining die, and/or trim die. Stage tooling can be cost effective for small quantity part needs.

The number of stages required to form a given part is generally based on the number of bends and holes in the part, and the order in which they must be created. Stage Tooling presses are the same as those used for Standard Press routings (see below). The tools tend to be simple, and a number of them can be incorporated within a die.

Tandem Die uses multiple presses (each with a single die) and automated transfer between presses. Tandem Die is similar to Stage Tooling, except that it uses automated transfer instead of manual transfer.

Progressive Die uses a single press (with multiple dies) and automated transfer between dies. All necessary stations are mounted on a single, common die set, and parts are transferred via a carrier strip with pilot holes.

Progressive die is a high volume sheet metal manufacturing process in which coil stock is fed through a sequence of stations, each of which performs a set of operations. Progressive die, like stage tooling, groups operations into stages (called stations in progressive die) by evaluating precedence and compatibility rules. However, whereas in stage tooling each stage corresponds to a separate machine, in progressive die all stations are housed within the same machine.

The progressive die process provides support for features and practices commonly used in automotive sheet metal manufacturing. These include deep draw forming operations, side-action forming (cam-actuated), support for multiple trim stages, and support for performing (hole) piercing operations prior to or subsequent to bending and forming operations, as well as additional options for specifying strip layouts and indicating concurrent stamping of multiple parts. These options generally are not available for stage tooling. Some large parts and parts that are very deeply drawn might be better handled by transfer die—see Sheet Metal—Transfer Die.

Standard Press uses a single press with multiple dies which are “switched over” for batch manufacturing of different operations (so only one die is used at a time). The Standard Press represents a batch manufacturing approach in which a single press is used to perform a certain type of operation on all parts in the batch, and then the die is switched out and replaced with another die to perform the next type of operation to all parts.

Standard presses vary greatly in size and can create complicated shapes out of large and small sheets of metal. The standard press is generally used for lower volume parts. In contrast, progressive die is generally used for high volume parts and assumes single-part flow.

Transfer Die uses a single press that contains multiple die sets. Transfer dies are special line dies that are timed together and properly spaced an even distance apart in a single press. The distance between each die is referred to as the pitch, or the distance the part must travel between stations. Parts are automatically transferred between stations/dies along special traveling rails mounted within the press boundaries. See Sheet Metal—Transfer Die for more information.

Possible operations in the various routing types include the following:

The hard-tooled stamping processes all are available via a separately licensed module.

If you have licensed the appropriate modules, your routing can include optional machining, turning, heat treatment, surface treatment, and packaging processes.

See Routing and Feasibility for Hard Tooled Sheet Metal for more information.