Rapid Prototyping Services for Metal Stampings
Wiegel's in-house prototype department is the proven choice for precision prototype metal stamping and low volume stamping components with tight tolerances. With over 80 years of experience, Wiegel prototypes parts for leading OEM and Tier manufacturers across aerospace, appliance, automotive, electric vehicle, electrical equipment, electronics, lighting, military and defense, solar, structural building components, and telecommunications industries, among others. Before investing in full production tooling, we validate design concepts at early phases of part development to perfect designs, confirm manufacturability, and prevent costly mass production issues. Our highly skilled engineers evaluate the feasibility of every part design and provide complete recommendations on the best-suited materials, design for manufacturability (DFM) improvements, cost savings opportunities for part and tool design, and the most appropriate manufacturing technology for each project. Prototype metal stamping saves time and money, produces quality parts with short lead times, and ensures best practices are in place before transitioning to full production.
Prototype Metal Stamping Capabilities
Our prototype metal stamping services utilize exclusive, in-house prototype technology developed by Wiegel engineers, along with wire EDM prototyping, waterjet cutting, 3D printing, and chemical etching. For short run metal stamping that accurately reflects final production parts, we use the same progressive die stamping equipment as full production, including high-speed progressive die stamping with Bruderer machinery and heavy progressive die stamping with Minster machinery.
In-House Tooling and Engineering Support
Wiegel's stamping facility features a fully equipped in-house tool room for building complex progressive die tooling, eliminating the need for an outside tool and die house and keeping lead times tight. Our engineers use Siemens NX 3D modeling software to simulate how prototype stamping parts and tools will function together in production before a single part is made. This allows our team to identify weak spots, flag design concerns, and implement modifications to improve manufacturability before cutting steel. The close alignment between our engineering and tooling teams means potential issues are addressed and resolved immediately, without the delays of outsourced tooling.
Prototype Assembly Services
For prototype assembly needs, Wiegel uses in-die assembly and secondary semi-automated assembly methods to combine multiple stamped parts and join plastic, metal inserts, or hardware components, including fasteners, screw machine parts, bushings, nuts, and studs to metal stampings. Our engineers also identify opportunities to replace hardware components with more cost-effective precision metal stampings, reducing part count and overall program cost.
Validate your design before full production. Wiegel's prototype metal stamping services deliver accurate, production-representative parts with short lead times, from concept to production-ready.
Metal Stamping Prototypes We Produce
Wiegel produces a wide variety of precision metal stamping prototypes and production parts from copper and copper-based alloys, precious metals, aluminum, and ferrous metals. We specialize in both precision electrical connectors and non-electrical metal stamped components for the world's most demanding consumer, industrial, and commercial applications.
Family owned and operated since 1941, Wiegel is capable of producing a range of custom, precision metal stampings with rapid prototyping prior to mass-production including:
- Brackets
- Brake Components
- Busbars
- Clips
- Compression Limiters
- Crush Bushings
- Engine Components
- Furniture Parts
- Fuse Boxes
- Fuse Clips
- Heat Sinks
- Hose Clamps
- Housings
- Lead Frames
- Lighting Components
- Press-fit PIns
- Printer Cartridge Blades
- Rolled Bushings
- Seat Belt Buckle (Steel Tongue)
- Selective Plated Lead Frames
- Selective Plated Terminals
- Sensor Components
- Shields
- Taillights
- Terminals, Contacts, and Connectors
- Transmission Components
- Transmission Lead Frames
- Wire and Cable Connectors
- Wire Formed Fasteners
- Wire Formed Hooks
- Wire Formed Springs
- Wire Formed Terminals
Prototype Metal Stamping Materials
Each metal has its own blend of mechanical, chemical, and surface properties, and selecting the right material is a critical step in the prototype metal stamping process. Our engineering and production teams have decades of experience working with a wide range of metals and developing the right tooling techniques to ensure the unique properties of each material yield the precise results our customers require. Materials we commonly prototype and produce metal stampings in include:
- Copper
- Brass
- Phosphor Bronze
- Beryllium Copper
- Steel
- Stainless Steel
- Carbon Steel
- Aluminum
- Galvanized Steel
- Titanium
- Platinum
Part Specifications Include:
- Minimum Part Length/Width: 0.25 in (6.35 mm)
- Maximum Part Length/Width: 24 in (609.6 mm)
- Part Diameter: 0.25 in (6.35 mm) to 24 in (609.6 mm)
- Part Thickness: .002 in (.051 mm) to .375 in (9 mm)
- Tolerance: +/- .001 in (+/- .025 mm)
Quality You Can Count On, Every Prototype and Production Run
At Wiegel, customer satisfaction starts with the quality and integrity of every prototype metal stamping we produce. In-die sensors, press monitoring systems, camera vision systems, and a dedicated inspection team work together to ensure every part leaving our facility meets or exceeds customer specifications.
Stamping Features
Stamping component features include automated in-die assembled, bi-metal, coated, coined, compliant pin (eye of the needle), countersunk, critical dimensions, EB welded, embossed, enameled, eyelets, flat, formed, heat-treated, IDC slots, inlay, multiple stamping, numbering, precious metal plated, reeled, shape critical, skived, strain relief, surface critical, surface mounted, tapped, threaded, tip coin and tuning forks.
Leading Technology and Equipment
Wiegel continually invests in advanced metal stamping technology to drive process efficiency and deliver high-quality, cost-effective parts. We operate progressive die stamping equipment from Minster and Bruderer, recognized leaders in stamping automation and press technology. Our equipment is built to achieve complex geometries and tight tolerances across both prototype and high-volume production runs. A dedicated automation department develops in-die sensor technology and camera vision systems that integrate quality assurance through every phase of stamping production. With an experienced team, innovative equipment, and superior quality controls, Wiegel delivers reliable progressive die high-speed stamping and heavy stamping services on time and on budget.
Partnership From Prototype to Production
Wiegel is known for building long-term partnerships through a co-engineered approach to collaboratively solving design and manufacturing challenges alongside our customers. Working directly with customer engineering and sourcing teams, we routinely co-develop solutions and identify cost saving opportunities across even the most complex prototype and production programs. Our goal is to optimize efficiency on every project by seamlessly bridging the workflow between customer teams and Wiegel. Decades of experience have shown us that the most cost-effective metal stamping programs are built on strong engineering collaboration from both sides. We strive to be a premier manufacturing partner and invaluable resource, driving efficiency across every phase of every project.
Quality
With Zeiss CMMs, OGP smart scopes and dedicated sensor and camera vision system technology to monitor stamping parts in and off production lines, our customers know quality assurance is our number one priority. We are IATF and ISO certified and have a dedicated quality lab and inspection team responsible for maintaining quality control at the greatest extent.
Learn MoreOur Technology
Wiegel lives by the philosophy of embracing the latest technology. We have regular technology updates and new equipment acquisitions so we can always have the necessary tools to develop breakthrough techniques and processes and deliver quality parts.
Learn MoreSupply Chain Management
From the very bottom of the supply chain, we manage product material, metal stamping production, pre- and post- stamping operations as well as product handling, tactical scheduling, logistics and delivery. Wiegel helps manufacturing customers reduce their supply base by offering assistance in all phases of metal stamping production from early design concepts to tooling to production of finished stampings and assemblies. Customers can track projects with real-time updates and keep all teams aligned with project goals.
Learn MoreIndustries
It’s our mission to offer premier metal stamping and metal forming solutions to the most challenging and innovative engineering product designs. We combine advanced metal stamping production and tooling equipment, superior quality controls, seamless automation and production processes, and a knowledgeable and experienced team to serve an array of market segments.
Frequently Asked Questions
Prototype metal stamping is the process of producing small quantities of stamped metal parts using methods like wire EDM, waterjet, or short-run progressive die tooling to validate part design and manufacturability before committing to full production tooling. It allows engineers to test form, fit, and function at a fraction of the cost of production tooling.
Wiegel's in-house prototype department is built for aggressive lead times. Turnaround varies based on part complexity and chosen process, but our single-source approach, tooling, prototyping, and production under one roof eliminate the coordination delays typical of outsourced prototype services.
Prototype stampings are produced in low volumes using flexible tooling methods such as wire EDM, waterjet, and chemical etching to validate the design before full tooling investment. Production stampings use dedicated progressive die tooling optimized for high-volume, high-speed output. At Wiegel, both use the same Bruderer and Minster press equipment, ensuring your prototype accurately reflects what production parts will look like.
Yes. One of Wiegel's core prototyping services includes identifying hardware components such as fasteners, bushings, screws, nuts, and studs that can be redesigned as more cost-effective metal stampings, reducing part count and supply chain complexity.
Wiegel works with copper and copper-based alloys, aluminum, ferrous metals, precious metals, and specialty/exotic alloys. Material selection guidance is part of Wiegel's prototyping process to ensure the best-suited metal for each application.
Prototype metal stamping costs vary depending on part complexity, material, tolerances, and the prototyping method used. Wire EDM, waterjet, and chemical etching typically carry lower upfront costs than progressive die tooling, making them well suited for early-stage design validation. Wiegel evaluates each project individually and recommends the most cost-effective prototyping method for your specific design and volume requirements.