Precision metal stamping offers a high degree of design flexibility for defining and implementing small features with tight tolerances and unique configurations, Custom applications are very well served by the adaptability of precision stamping with tooling that is tailored to the exact requirements of each application.
However, sometimes it pays to not be totally unique with the tooling approach. The use of "Open Tooling" for creating stampings that share some basic characteristics can offer excellent opportunities for both reducing the cost of the tooling and improving the time to market. 
In fact, our experience has shown that using this approach for press-fit, RF shielding and antenna components can cut the tooling cost by as much as 50 percent and reduce the lead time by 60 percent or more.
Open Tooling is essentially a process of looking for common elements across products within a category and then building a master die that readily accommodates these elements while leaving ample flexibility for implementing product-specific features and dimensions. The basic architecture of the master tooling is reusable across multiple products by using tooling inserts to accommodate the specialized requirements.
Key product categories for leveraging open tooling include:
- RF antennas for wireless products
- RF shielding for EMI control and signal integrity
- Press-Fit solderless interconnect components
Stamped antenna components are used across a wide range of wireless products in many industries, ranging from automotive applications to consumer products. With the proliferation of interconnected wireless applications, such as intelligent automobiles and Near Field Communications (NFC) between mobile devices, manufacturers need antenna fabrication methods that can adapt to specific requirements, such as frequency specifications, but still be highly manufacturable for low costs and high volumes.
Antennas tend to vary in their length and height to tune for specific frequencies but they share common characteristics in other dimensions (width and thickness). This makes the reusable tooling approach an excellent way to cut lead times and tooling costs for stamped antennas.
Similarly, RF Shields typically have X-Y dimensions and individual hole sizes and locations specified, but other characteristics are not critical to the shield functionality. Therefore, the use of a common tooling master die in conjunction with product-specific die inserts can dramatically reduce both cost and lead times.
For Press-Fit interconnects, the key variables are length and tip configurations. Using Open Tooling with inserts for these variable features can cut the lead times for press-fit components from as much as 22 weeks to as little as 8 weeks.
In addition, Open Tooling can readily accommodate a range of different alloys, platings and other metallurgic characteristics so designers can easily tailor any of these aspects of their products to meet application-specific requirements.
To learn more about reducing the cost and lead times for specific applications, visit Interplex Sunbelt.
