Penn Metal Stamping, Inc.

United States

At Penn Metal Stamping, Inc., we are an ISO 9001:2008 certified manufacturer of high-quality stamped parts serving a diverse range of both North American and international companies. With our strong capabilities in manufacturing and quality engineering, we develop innovative methods for stamping parts with complex geometries and close tolerance requirements. From design and prototyping through to volume production, packaging, and shipping, we manage jobs efficiently and promptly.We operate a modern, well-equipped facility and are proficient in all stamping processes, such as continuous strip, compound die, progressive die, deep draw, and more. With our powerful technical capabilities, we continually develop inventive new strategies for stamping everything from intricately detailed micro-sized parts all the way to large, heavy gauge components with complicated features and critical shapes and surfaces.In addition to a full range of metals, including high strength alloys and exotics, we stamp parts from fiber composites, rubber, materials such as PVC and PTFE-based resins, and many others. Our tooling is designed to minimize set-up, optimize cycle times, and ensure efficient, defect free production. We have an impressive inventory of test, measurement, and inspection equipment and emphasize quality at every step of the production process.We have the capacity to manage projects of any size and offer additional services, including finishing and assembly. Kanban programs, just-in-time delivery, as well as on-site and off-site inventory management are all available to support your logistical needs, and our production software allows us to exchange information electronically to expedite order management and tracking. To ensure timely delivery, we have developed a responsible and reliable infrastructure for both domestic and overseas shipment.With our technical capabilities, attention to detail, and quality-driven production methods, you can be confident that your stamped parts will be delivered on-time and on-specification with all supporting documentation. Contact us today to learn more.

Skillfully developed and expertly executed tool and die designs are the foundation for our high-quality custom stampings. At Penn Metal Stamping, Inc., we design and build almost 100% of the tooling and fixturing we use in-house. We also manufacture dies, inspection gauges, as well as and checking, welding, and assembly fixtures for outside clients.Our tool and die professionals have grown up in the industry are up-to-date on all of the latest software tools and production technologies. Using sophisticated CAD design programs, we develop novel and innovative concepts that ensure quality-driven, defect-free production, accelerate cycle times, and minimize waste and scrap. Solid modeling and simulations allow us to refine and validate tooling and fixture designs prior to production, which eliminates adjustments and re-work that could impact production timelines.We operate a fully equipped tool and die shop and utilize high-end test and inspection instrumentation to ensure tool quality for accurate and consistent part production. Materials of construction are chosen based upon the expected product lifecycle, and we can modify existing tooling to comply with alterations or variations in product design. Our comprehensive preventive maintenance program ensures tooling is always production-ready, and we document all repairs and modifications throughout the life of your tooling. In addition, we keep an inventory of spare tooling components on hand to minimize downtime and keep production running at full capacity.

At Penn Metal Stamping, we provide customized assembly solutions for companies requiring high quality finished goods at affordable prices. By placing product assembly in our hands, your goods will be completed quickly and accurately while your costs remain predictable and controllable. We have the capacity to stream finished products into your production flow at varying rates to match the ebb and flow of demand. In addition, you are assured that every aspect of your product is tested, measured, and inspected to meet your quality requirements.We have the tools and experience to build a diverse mix of products, including complicated automotive steering systems, exhaust flanges, welded structures, electronic assemblies, even simple mated parts. Our assembly professionals have the expertise to interpret complex schematics and choose the best and most efficient methods to build your product. They break down assembly projects into a cohesive set of tasks, which are assigned to fully qualified and trained staff. We have an extensive inventory of assembly tools and machinery for crimping, soldering, welding, press fits, and much much more. Quality is integrated into every step of the process to ensure that all items meet or exceed specifications.By leveraging our technical competencies and high standards of excellence, you can free up your internal resources to focus on your core business. We can ramp up capacity as your business grows and help you deliver products with improved quality and integrity. We are ISO certified and adhere to numerous industry standards and best practices. Packaging and shipping are completed according to your standards using methods that are both convenient and cost effective.

Project description: Gauge and Visually InspectAt Penn Metal Stamping, Inc., we devote a lot of square footage in our facility to our test and inspection area. It is filled with a large inventory of up-to-date metrology equipment and staffed by a strong team of trained professionals. With our ISO certification and high-quality ratings, we have a growing number of customers who leverage our 3rd-party inspection capabilities to implement their Safe Launch Programs.One of our clients in the region contracted with us to gauge and visually inspect the gear highlighted in the photograph shown here. The purpose of the Safe Launch inspection was to validate for their automotive industry customer that their processes had the stability to produce a very high rate of conforming product. By collecting and analyzing inspection data, we could help our client pinpoint areas where adjustment might be needed.Following our robust set of protocols, we used a variety of gauging methods and high-resolution micrometer measurement to document product quality. We compared these to the drawings to validate that all dimensional aspects of this gear, which measured 2.0" in diameter, were within the specified .0015" tolerances.Since test and inspection tasks take place as projects are approaching the finish line, timeliness is always of utmost importance. Despite the high volume of product, we were able to process the inspection and prepare the documentation within one day. Our prompt turnaround allowed the client to meet their internal deadlines and obligations to their customer. Our highly rated performance on this project has led to additional business from this client.

Project description: Grounding Strap used in railroad applicationWith our depth of expertise and efficient methods for product manufacturing and assembly, Penn Metal Stamping, Inc. provides cost-conscious solutions that effectively compete with prices from offshore vendors. Also, by being in close proximity to a client, we can easily collaborate with their internal teams on design issues. We are often able to make recommendations that improve quality and manufacturability while significantly trimming production timelines.The railroad grounding strap shown here consists of two stamped metal terminals, tin plated copper wire braided cable, and black tubular insulation. While reviewing the drawing, we identified that altering a few design elements would improve the overall quality of the product while facilitating manufacturing and assembly. The client was very pleased with our recommendations and price so they awarded us the contract.Production involved several coordinated process flows. Along with cutting the wire and insulation to size, we proceeded with the tooling and stamping of the metal terminals. The manufactured components converged into the assembly area, where our press operators joined the four pieces into a finished ground strap assembly measuring 5.0" in length. In addition to in-process inspection of the individual parts, we pull-tested the finished straps to ensure their strength and functional integrity.One extremely favorable aspect for the client was the short amount of time it took us to complete this project. Our comprehensive capabilities allowed us to deliver a moderate volume of product to them within a one-week turnaround, substantially faster than an overseas vendor would have accomplished. The client was very impressed with the results, and we were pleased to acquire a new and satisfied client.

Project description: Retainer Plate used in automotive transmissionAt Penn Metal Stamping, Inc., manufacturing, inspection, and assembly of critical parts for the automotive industry is one of our core strengths. We have an in-depth understanding of the production part approval process (PPAP) and the important role it plays when doing business with this industry. Our familiarity with the process allows us to cost-effectively compete with larger suppliers while offering the level of prompt, reliable, and personalized service that as a small business we excel at providing.We manufactured the transmission retainer plate components shown here for a major automotive company. These parts had very detailed features that we needed to reproduce accurately and repeatably in thick gauge materials. The ingenuity of our design engineers allowed us to develop unique, non-standard tooling and fixturing that enabled us to overcome the difficulties associated with stamping geometrically complex shapes. Constructed from steel, we were able to uphold tolerances as close as .0015" on all dimensional aspects, including flatness. Our production process also involved deburring to remove any shards remaining after the stamping process and improve the quality of the finished part.Quality assurance is a dominant activity in our shop. From the sheet metal that came in the door, to die manufacture and upkeep, press maintenance, and process controls, we built quality into every aspect of this stamping process. We prepared all the required PPAP documentation and applied a rust preventive coating on the retainer plate components to protect them during shipping and storage.

Project description: Aluminum Cap used in steering systemThe aluminum cap highlighted here is an example of a product we produced in high volume here at Penn Metal Stamping, Inc. Used as a component in an automotive steering system, it features close tolerance, thin gauge construction. One of our challenges for this project was developing packaging to protect the cap during overseas shipment to China.Due to the size and shape of the component, we ran several prototype runs to ensure the stability of our process and to validate that the product conformed to specification. Production involved deep draw stamping combined with a pinch trim cut-off to provide a clean surface on the open end. When completed, the housing featured dimensions of 1.5" in length x 1.0" in diameter x 0.010" in thickness. Our quality assurance procedures involved dimensional gauging to ensure we accurately and repeatably met the tight .0015" tolerance requirement for this high volume application.The narrow gauge construction of these parts made them very fragile. We designed a custom method for packaging these items to achieve two goals. One was to protect them during transport; the other was to optimize the packing density for cost-effective bulk shipment overseas. Although we are a small business in Pennsylvania, the quality of our work has earned us an international reputation, so we are familiar with all of the process and paperwork involved with worldwide freight handling. The aluminum housings arrived safely at their destination in China, and the client was very satisfied with the quality and timeliness.

The helical gear assembly highlighted on this page was produced completely here at Penn Metal Stamping, Inc. For this project, the client supplied the pulley while we were responsible for manufacturing the flanges and assembling the final product.We stamped the flanges from carbon steel, which provided the high strength properties required while being ductile enough to be reformed during assembly without losing its toughness. Assembly involved joining one of these steel flanges to each end of the supplied helical pulley gear, which was manufactured from powdered metal. Our engineers developed a method to do this using innovative tooling and a material displacement process on the assembly press. This swaging process allowed us to alter the diameter just enough to form a permanent fit of the metal components. We used an advanced technology control and monitoring system on the assembly press to ensure that the stroke forces were consistent over the entire production run and from lot to lot.Once we assembled the components, further quality assurance involved various inspections to ensure tolerances were within .002". We also physically pulled apart samples of the finished product to measure the forces needed to break the strength of the bond. This destructive-type testing gave the client confidence that the products would perform as intended and avoid the possibility of in-field failures. Prior to shipment, we applied a dry-to-the-touch rust inhibitor to protect them during transport and storage.We produce these parts at the rate of 700, 000 per year, in batches that we turn around on a two-day basis, and the client has since rewarded us with additional business.

Project description: Design and build weld fixtures for customersThe tool shop in our facility here at Penn Metal Stamping, Inc. is a busy operation. In addition to building dies and fixtures for our own internal use, we build and repair tools for outside clients. Designing and building tools and fixtures is a complex process that is managed by a group of individuals with a broad skill set. They use sophisticated software programs to design, refine, and validate functionality, and then use many different types of machines and other equipment to reproduce their designs in metal. Since tools and fixtures typically have very close tolerance requirements, the process of machining, measurement, and inspection is done with diligence and attention to detail.The weld fixture shown here is an example of one such project we recently completed in our tool shop. Designed for use on an electrode-welding machine, it featured copper construction to promote welding stability. No detail was overlooked during the design phase to ensure the fixture would allow for repeatable accuracy at maximum production rates. We also designed and built this fixture to withstand prolonged stress with minimal maintenance requirements.Our technicians use our high-tech machining center, wire EDM, and soldering equipment to build and assemble the fixture. When complete, the main body measured 2.0" in length x 2.0" in width. In addition to numerous in-process inspections, we performed a leak test to ensure the fixture was fully sealed.Through the efforts of our engineering team, tool shop technicians, and quality analysts, we manufactured a single version of this fixture within a very short two-week timeline. Feedback from the customer has been exceptionally positive.