The Revolution in Stamping Technology: High-Performance Automation and the Rise of Supermolds
In the world of stamping, technology has always played a crucial role. However, without a corresponding level of excellence in mold design and manufacturing, even the highest-speed automation can fall short of its potential. In this blog post, we will explore the importance of ensuring quality and the innovative solutions that Bruderer and Stepper have brought to the market.
The Power of High-Performance Automation
In the pursuit of efficiency, manufacturers are constantly seeking ways to streamline their processes and improve productivity. High-performance automation is a key factor in this quest, and Bruderer’s sales are a testament to this. The company’s commitment to innovation and excellence has made it a leader in the industry, particularly in the region around Pforzheim, Germany.
A Leading Example of Joint Solutions
A recent collaboration between Bruderer and Stepper, a South Korean client, exemplifies the benefits of high-performance automation. The client, a leader in subcontracting projects, was seeking a high-speed automated punch press to meet production requirements of 350 million pieces per year. After considering various offers, the company chose Bruderer’s technology, partnering with Fritz Stepper & Co. AG in the Pforzheim region.
From 400 to 800 Strokes per Minute: The Impact of High-Performance Stamping
Prior to the deployment of Bruderer’s technology, the client’s existing punches worked at a speed of 400 strokes per minute, 7 days a week, and 24 hours a day. By contrast, their new setup, using Bruderer and Stepper’s combined production equipment, achieved a staggering 800 strokes per minute. This resulted in a remarkable 1,600 pieces per minute, thanks to the rationalization effect.
The Role of High-Quality Molds
Michael Stepper, director-general of Fritz Stepper & Co. AG, emphasized the importance of high-performance molds: "Speed is not everything; it starts with requiring the right equipment and high-quality molds." The Bruderer punch press, with its high-rigidity design and precision engineering, is a testament to this philosophy.
Stepper’s Innovative Products
Stepper’s product range can be categorized into three areas:
- Proto series: Designed for prototype-type traction matrices with short lead times.
- Modular 1 module molds: For effective production of small to medium-sized series of products.
- F1 Supertec: For massive production with the best production efficiency, featuring "supermaterials," "supertechnology," and "supercoating."
Michael Stepper is proud of the revolutionary innovations in mold design and manufacturing, which began with his father’s groundbreaking work in the mid-1970s. He is also proud of the development of F1 Supertec products, a pioneering initiative in the mold industry.
The ‘Super Materials’ Revolution
Innovative materials, such as hard metal particles, lay the foundation for a stable blade, ensuring a long product lifespan and meeting various critical factors. These factors include:
- Surface supersurface technology: Enabling treated products to have a RA0.01 μm surface roughness and a profile tolerance accuracy of 1 μm.
- Spray installation: With a surface hardness of up to 5000 HV.
The F1 Supertec mold boasts high precision and high productivity, as demonstrated by Michael Stepper: "This innovative project is a prime example of the argument that using ‘made in Germany’ mold technology is still profitable and benefits the world."
Conclusion
In the ever-evolving world of stamping technology, innovation and excellence are paramount. The collaboration between Bruderer and Stepper has set a new standard for high-performance automation and mold design. As we continue to navigate this rapidly changing landscape, we must stay focused on ensuring quality and leveraging cutting-edge technologies to drive productivity and success.
