Imagine a tool so precise that it can shape metal into intricate components. And these components can then be used in all industries from automotive to medical devices. Such a tool is called a precision die. The simpler term "punch" is also often used. These dies are essential for various forming processes such as punching, pressing, bending and deep drawing. They play a crucial role in the production of metal components for industries such as

• Automotive industry
• Plastics
• Electric
• Textiles
• Medical technology

Every year, the complexity and quality requirements for these parts increase, meaning that high-quality, intelligent tooling is the key to maintaining competitiveness. Precision die measurement is one of Bruker Alicona's core competences. Here you get some additional insights. 

Accurate measurements are the backbone of quality assurance in the production of precision dies. Here's why:

Various aspects of the production of molds and dies are measured to ensure quality:

In the world of precision die manufacturing, different companies have different needs. Some companies focus on the production of end products and often have their own tool shop, while others specialize in the supply of tools or individual manufacturing processes. There are also hybrid models that combine both approaches, i.e. manufacturing end products and supplying tools to other companies. Understanding these different needs is critical to providing the right measurement solutions that increase efficiency, ensure quality and drive success, which is Bruker Alicona's goal.

Progressive dies combine the technically different processes of stamping and forming technology. In order to guarantee the quality of the component, the tool must work precisely and all production steps must be perfectly coordinated. Precise bending angles, punching depths, tight tolerances and high repeat accuracy are required. Component geometries are becoming increasingly complex, and processes need to be faster, more energy-efficient and more economical.

A punching tool or progressive die has a highly complex structure consisting of various tool plates, plate inserts, dies and punches or embossing and bending tools. The workpiece is transported from stage to stage by the carrier belt and separated from the belt in the last stage. High stroke rates and short set-up times can keep unit costs low. The stroke rates of progressive dies are 45 to 55 strokes per minute for simple and flat parts.

The shaping geometry is the most critical area of a die and is manufactured with the greatest possible precision. Maintaining the basic shape accuracy and position in relation to the mounting surfaces is critical. Punches can be mounted in a variety of ways, including geometric clamping, bolted connections, form-fit fasteners and quick-change systems. Reference surfaces are essential as they serve as fixing points or references for the production of fixing points.

Smooth replacement of punches with consistent component quality is essential. High demands on dimensional accuracy, shaping and surface quality must be met. Consistent quality across multiple injection molding machines is required. Tolerances <10µm require high machine accuracy and expertise.

Bruker Alicona uses Advanced Focus-Variation and Vertical Focus Probing technologies for data acquisition. These methods enable highly accurate measurements on a variety of surfaces, even highly polished or reflective ones pose no challenge. The user interface for these solutions is MetMaX metrology software, which breaks the measurement process down to just a few clicks. Using your CAD files, which may even already contain PMI, the measurement strategy can be generated automatically, taking into account the deviation of the surface from the shape, the reference points and the offset data of the production machine.

Data acquisition includes a complete scan of the forming geometry and a partial measurement of the lateral surfaces using these advanced techniques. With the Advanced Focus-Variation, complex shapes and shiny surfaces, which are often found on punches, can be measured with little effort.

The high-precision measurement offers several advantages.

• Early detection of dimensional inaccuracies prevents faulty production
• It supports process optimization through the correct interpretation of influencing factors.
• It is proof of the quality of the end product, as the stamp is decisive for the shape.
• It reduces waste by ensuring the exact geometry of the die.
• Ensures an indisputable representation of the production chain of the end product.

In the competitive world of precision toolmaking, quality assurance is the key to success. By using advanced 3D optical measurement techniques, manufacturers can ensure the highest levels of precision and quality in their products. For more information on how Bruker Alicona can support you in gaining the highest quality for your precision dies click here. Or download a measurement report to see the results you get from a Bruker Alicona device.