Using high-viscosity fully synthetic stamping oil that is rich in extreme pressure additives (EP), and a micro-volume lubrication (MQL) system, is the ultimate technical solution to the elimination of surface scratches and localized tensile deformation during heavy-gauge Kovar stamping service.
Problems with Traditional Lubrication Methods
Traditional lubrication solutions are entirely at odds with process requirements of thick-plate Kovar stamping service and are very likely to cause part defects. Unlubricated or poorly lubricated workpieces of thick-plate stamping get damaged surfaces. When Kovar thickness surpasses 1.5mm, conventional lubrication shows a lot of limitations:
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Weak, easily broken emulsion oil film, resulting in direct metal-to-metal contact.
Non-uniform lubrication, this way leading to localized high temperatures and surface scratches.
Stubborn oil residue that is difficult to clean and later affects welding and electroplating.
This is the key point explaining why high precision Kovar stamping service require custom lubrication strategies.
LS Manufacturing Tailored Lubrication Solutions
We have done a different process of creating lubrication strategies for different thicknesses and formation difficulties. Lubrication matching by targeting leads to the enhancement of the surface of heavy-gauge stamping parts:
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Thickness < 1mm: Low-viscosity fully synthetic stamping oil can be used with mist lubrication.
Thickness 1-3mm: The use of chlorinated extreme pressure lubricant with a viscosity of 150mm/s at 40℃ is recommended.
Thickness > 3mm: The composite lubrication technique of oil film pre-coating + micro-spraying is capable of achieving a surface roughness Ra < 0.4μm.
The customized lubrication scheme we have designed has been more exactly targeted at the problem of surface damage during the stamping Kovar and Invar parts, and it ensures the surface precision and airtightness of the parts.
How to Evaluate Scaling Costs for an Invar Precision Stamping Project?
In order to measure the cost of mass production for Invar precision stamping. It helps to find a good mix between the high upfront investment in progressive dies and the cost of machining per piece. Generally, if the MOQ is set to 5000 pieces or more, stamping could cut the total cost down by 50% to 70% over the time-proven CNC machining.
Cost Structure Comparison of Different Processing Technologies
We have formulated a straightforward multi-level cost accounting model. A sensible choice at the process level can go a long way in controlling the all-inclusive cost of a stamping job.
Specific comparison data is as follows: (Unit: USD)
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Processing Technology
500 Pieces
5000 Pieces
50000 Pieces
マテリアルの利用
Production Cycle
CNC Milling + Wire EDM
125.0
98.0
85.0
<15%
4-6 weeks
Single Die Stamping
42.0
28.0
22.0
65%
2-3 weeks
Multi-Station Progressive Die Stamping
68.0
18.0
12.0
>90%
1-2 weeks
Professional Invar precision stamping technology can bring about remarkable cost and efficiency benefits when used for high-volume production versus traditional processing methods.
LS Manufacturing's Approach To Cost Optimization
We work with clients to ensure that every penny they invest translates into maximum returns. Scientific cost planning is a tool to increase the profit margin of batch stamping projects:
Furnish detailed DFM cost cutting solutions, which typically bring about a 15% reduction in part costs.
Give advice on proper mold investment strategies based on customers' life cycle projections.
Provide mold installment payment plans that can help to release the capital burden upfront.
If you are looking for mass production of parts made from low-expansion alloys, high-performance, and high precision metal stamping service are clearly the best choice. Based on sophisticated cost optimization solutions and closed-loop processes, we are a reliable high-quality stamping service partner for cost-effective mass production.
How Do You Vet a Low Expansion Alloy Manufacturing Partner For Custom Kovar And Invar Progressive Stamping?
Choosing a dependable and capable low expansion alloy manufacturing manufacturer not just one supplier, but a thorough verification of three major criteria is needed: the dynamic clearance of the mold should be stably controlled within 0.002mm, the manufacturer must have a 1050℃ vacuum hydrogen annealing furnace independently, and the manufacturer must provide on-site SPC quality data reports with Cpk1.33.
Typical Capability Deficiencies of Regular Stamping Workshops
Generally, most of the regular stamping workshops are far from capable of low-expansion alloy processing. A lack of dedicated process experience results in substandard production of the special metal stamping:
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Using stainless steel stamping parameters, the stamping clearance is too large, because of this causing edge cracking.
Due to the unavailability of vacuum annealing facilities, the manufacturers are compelled to outsource, which further results in loss of control over the quality.
Absence of high-precision measuring instruments makes staying consistent with the dimensions a nightmare.
Only a fully closed-loop production process can ensure good-quality low expansion alloy manufacturing, merely the stamping step alone will not be able to result in a quality product. This is the main reason why it is obligatory to check the full chain process capability while choosing a reliable stamping service provider.
LS Manufacturing's Full-Chain Advantages
We bring all the main steps of our work into one factory. This way, we can guarantee high-precision and reliable stamped products delivery by using a closed production system:
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Mitsubishi wire EDM is our main tool, so we keep mold processing tolerance to 0.005mm.
We have three independent vacuum hydrogen annealing furnaces capable of 1050℃, which gives us a large production capacity.
We have digital full-process traceability, so any batch of products can be tracked back to the original raw material batch.
Having a well-developed closed-loop system of precision metal stamping service completely gets rid of the quality risks of outsourcing. Our keenly focused process R&D and manufacturing system enable our Kovar stamping service to be much better than usual manufacturers in the industry.
Case Study: How LS Manufacturing Rescued a Telecom Giant's Optical Transceiver Kovar Base Plate Project?
Customer Challenges
A reputable North American optical communication firm wanted to develop an 800G optical transceiver and because of this required a customized, high-precision Kovar base plate substrate with a thickness of 0.8 mm. At first, they went with a conventional stamping factory that resulted in large cracks at the edges of the parts due to huge blanking clearances and absence of a follow-up vacuum annealing procedure.
Even with a springback that was strong enough to cause a flatness deviation of as much as 0.05 mm, cracking at the solder joints of the chips came to 18.5% after the environmental testing at -40℃ to 85℃, which pushed the production to shut down and led to a more than $100,000 daily production loss.
One of the main issues with ordinary stamping manufacturers is their total lack of process control capabilities when it comes to high precision Kovar stamping services, and as a result, they fail to meet production standards of highly precise optical communication components.
LS 製造ソリューション
Within two days, our R&D team managed to perform DFM analysis and undertake the mold redesign. We utilize a five-station precision progressive die, with carbide punches coated with DLC film (friction coefficient 0.1), allowing us to precisely lock the punching clearance at an incredibly refined golden ratio of 6%. At the same time, we rolled out our self-developed 1050℃ precision temperature-controlled hydrogen-protected vacuum annealing process, so completely eradicating work hardening and residual stress.
結果と値
Upon the completion of three consecutive batches of mass production verification, containing 20,000 pieces each, the product's first-pass yield was 99.8%, and in the thermal cycling test, the solder layer cracking rate was brought down to zero. The flatness that was at 0.05 mm got better to within 0.01 mm, so fully complying with the optical transceiver's optical path coupling requirements.
By far, the biggest impact is that by using our stamping technology, the customer's unit processing cost got directly cut down by 64%, and the delivery time got shortened by a whole three weeks in comparison with the initially planned CNC machining solution. The very successful client, in the end, named LS Manufacturing as its only global strategic supplier of Kovar substrates.
The top-quality low-CTE stamped parts production solution on a large scale that was implemented this time had perfectly resolved the customer's mass production failure and cost issues, as a result, we became one of the main stamping service partner that the customer trusts for a long-term basis.
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If you are also facing similar mass production difficulties, immediately schedule a one-on-one technical consultation with our senior engineering experts to quickly solve your project problems.
よくある質問
Q1: What is the normal lead time for a tailor-made Kovar stamping service project at LS Manufacturing?
After you upload the drawings, we will complete the DFM evaluation and quotation within 5 working days. The time for delivery of one mold and the first batch of samples is 15-20 days and for high-precision multi-station progressive dies 25-30 days. Mass production delivery can be done within 7 days after sample approval.
Q2: Can Invar precision stamping material magnetization and if so, how do you get rid of it?
Yes, cold stamping of high stress can induce lattice transitions and produce weak magnetism. We perform a 900℃ hydrogen stress-relief vacuum annealing that gets rid of magnetism completely and at the same time, the original ultra-low coefficient of thermal expansion is restored to 100%.
Q3: What is the Minimum Order Quantity (MOQ) for high-precision Kovar stamping service parts?
We offer prototype production with a minimum of 100 pieces (combining precision wire cutting and single-shot die), the minimum order for progressive stamping with formal die opening is 2000 pieces to get the most out of the die costs through amortization.
Q4: How can LS Manufacturing ensure that production complies with IATF 16949 and ISO 9001?
Our companies' systems strictly follow IATF 16949 and ISO 9001 standard. For every batch, we carry out material spectral analysis, full-stroke SPC monitoring, and we also deliver full coordinate measuring machine reports and certificates of conformity.
Q5: Can you machine and stamp Kovar and Invar parts with selectively plated or cladded coatings?
Sure, we provide a comprehensive surface engineering solution that can be stamped and processed with pre gold-plated, nickel plated, or copper coated composite strips. The coating is protected from peeling or flaking through a special mold structure.
Q6: How does the raw material price fluctuation of Nickel and Cobalt affect my stamping project quotation?
The prices of Kovar and Invar fluctuate broadly in response to the international nickel and cobalt futures prices. To offset a part of these fluctuations, we put in place strategic procurement agreements with leading steel mills that allow us to fix the core material price and offer a price lock-in period of 3-6 months.
Q7: What are the maximum material thickness capabilities for your low-expansion alloy manufacturing lines?
With some of our presses capable of 300 tons, our precision stamping lines not only can handle simple stamping but alsodeep drawing and multi-angle bending of materials varying from 0.05mm super thin shielding foils to 4.5mm heavy-duty microwave waveguide substrates.
Q8: Why should I choose LS Manufacturing as my stamping service partner instead of a general stamping shop?
Besides general stamping shops not having the engineering knowledge necessary for stamping high-hardness alloys, at LS Manufacturing we have spent 20 years focused on 0.005 mm tolerance limits, low CTE material control, as well as having a complete proprietary vacuum annealing and testing closed-loop system.
概要
At first Kovar and Invar precision stamping were, in fact, considered support processes and inducement price cuts by automakers only. When optoelectronics, semiconductors, and microwave packaging became high-end manufacturing industries, Kovar and Invar precision stamping as key business processes appeared for cost reduction, efficiency improvement, and product temperature stability guarantee. LS Manufacturing distinctively through the use of accurate blanking clearance control, wear-resistant dies with unique designs and a complete, closed-loop vacuum annealing process has solved the main industry issues such as part cracking, CTE failures, dimensional deviations by ensuring stable operation of precision components in extreme high and low temperature environmental conditions.
Don't allow old-fashioned processing methods and unreliable small workshop suppliers to slow down your new product launches or eat away your project profit margins. Call the senior, high-level difficulty materials engineering experts at LS Manufacturing now.
You just need to upload your 3D STEP drawings or 2D DFM design sketches with one click, and our professional staff within 24 hours will provide you with a very detailed technical quotation including process feasibility study, tiered mass production cost calculation, and a complete die amortization schedule.
Request your FREE DFM evaluation and customized stamping quotation now and we will be your most trusted and remarkable support in low-expansion alloy precision manufacturing!
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LS 製造チーム
LS Manufacturing は業界をリードする企業です。カスタム製造ソリューションに焦点を当てます。 We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. 金属スタンピングやその他のワンストップ製造サービス。 当社の工場には、ISO 9001:2015 認証を取得した最先端の 5 軸マシニング センターが 100 台以上備えられています。当社は、世界 150 か国以上のお客様に、迅速、効率的、高品質の製造ソリューションを提供しています。少量生産でも大規模なカスタマイズでも、24時間以内の最速納期でお客様のニーズにお応えします。 LSマニュファクチャリングを選択します。これは、選択の効率、品質、プロフェッショナリズムを意味します。 詳細については、当社のウェブサイトwww.lsrpf.comをご覧ください。
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