Metal stamping is an essential manufacturing process that produces precise, complex parts with high repeatability. From automotive to medical devices and electronics, countless industries rely on stamped components for efficient, high-volume production. However, the cost of producing these stamped parts can quickly escalate if proper planning, design, and supplier selection aren’t handled strategically.
In this post, we’ll explore practical ways to reduce the cost of metal stampings without compromising quality or performance. We’ll also highlight how Larson Tool & Stamping Company, a trusted name in precision metal forming, helps its customers achieve cost-effective results through engineering expertise, state-of-the-art technology, and a customer-centric approach.
Understanding the Cost Factors in Metal Stamping
Before diving into cost-saving strategies, it’s essential to understand the key drivers behind the cost of metal stamping:
- Material Costs
Raw materials—whether stainless steel, aluminum, brass, or exotic alloys—are often the largest expense in stamping. The type, thickness, and grade of material significantly affect overall cost. - Tooling Costs
The upfront investment in dies and tooling can be high, especially for complex parts. While these are often amortized over the production run, they still represent a major factor in the project budget. - Production Volume
Economies of scale play a big role. Larger production volumes reduce per-unit costs due to the distribution of setup and tooling expenses over many parts. - Part Complexity
Complex geometries may require multiple forming operations, secondary machining, or more expensive tooling—all of which add to the cost. - Labor and Setup Time
Setup, die changeovers, inspections, and secondary processes all impact labor costs. - Scrap Rate
Inefficient nesting or tooling design can result in high scrap rates, wasting valuable material.
Strategies to Minimize the Cost of Metal Stampings
1. Design for Manufacturability (DFM)
Engaging in DFM early in the design process is one of the most effective ways to control costs. Collaborative engineering between the customer and the stamping supplier can identify opportunities to:
- Reduce part complexity
- Eliminate unnecessary features
- Standardize material thicknesses
- Optimize tolerances
At Larson Tool & Stamping, experienced engineers work closely with customers to improve part designs for stamping. Our proactive DFM services often uncover hidden cost savings before production even begins.
2. Optimize Material Usage
Material selection is not only about performance—it also plays a pivotal role in cost control. Considerations include:
- Using thinner materials where feasible
- Substituting lower-cost alloys that meet functional requirements
- Minimizing waste through better nesting or strip layout
Larson Tool’s in-house tooling design and simulation capabilities allow us to maximize material efficiency. Our engineers use CAD and forming simulation software to analyze the strip layout and identify the most efficient material usage.
3. Leverage Progressive Die Stamping
Progressive die stamping is ideal for high-volume production of intricate parts. It integrates multiple operations—such as punching, bending, and coining—into a single tool and run.
This approach reduces:
- Setup and labor time
- Secondary operations
- Handling and inspection costs
Larson Tool specializes in progressive die stamping and have many presses capable of running progressive dies up to 450 tons. Our extensive progressive tooling capabilities allow us to produce complex components in fewer steps, often with zero secondary operations—translating to substantial cost savings.
4. Consolidate Operations
Each additional forming or machining operation adds cost. By combining multiple processes into a single die or run, customers can significantly reduce:
- Production time
- Tooling costs
- Part handling
Larson offers deep draw stamping, coining, forming, and tapping within the same facility. We frequently design multi-functional tooling that accomplishes several operations in one stroke, maximizing value per cycle.
5. Select the Right Partner
Choosing a stamping partner who prioritizes efficiency, automation, and quality control makes a significant difference in cost and outcome. Look for:
- In-house tool design and maintenance
- ISO-certified quality systems
- Advanced material handling and feeding systems
- Automation to reduce labor
Larson Tool & Stamping excels in these areas. As an ISO 9001:2015 certified company, Larson maintains strict process control and offers turnkey services, from tool design to final inspection and assembly. Our in-house toolroom ensures minimal downtime and lower costs over the long term.
6. Plan for Scale
Prototype runs are important for validation, but planning for full-scale production upfront can lead to cost efficiencies. Larson helps customers transition from prototypes to volume production with tooling and process scalability in mind, ensuring that the final setup is optimized for large runs.
Why Larson Tool & Stamping Stands Out
Larson Tool & Stamping isn’t just another stamping vendor—we are a strategic partner for companies seeking cost-effective, high-quality stamped components. Here’s what sets Larson apart:
✔️ Over 100 Years of Experience
Founded in 1920, Larson has over a century of expertise in precision metal forming. This longevity reflects our ability to adapt, innovate, and consistently deliver value.
✔️ In-House Tool Design & Build
Larson designs and builds all tooling in-house, reducing lead times and ensuring tool longevity. Our toolmakers understand production environments, resulting in dies that are built for durability and efficiency.
✔️ Advanced Press Capabilities
With over 30 stamping presses—including mechanical, hydraulic, and servo-driven—Larson handles everything from miniature parts to large, deep-drawn components.
✔️ Deep Draw Expertise
Few companies have Larson’s proficiency in deep draw stamping, which allows the creation of seamless, high-strength parts with minimal material waste.
✔️ Scalable Manufacturing
Larson supports a range of production volumes, from small pilot runs to millions of parts annually, offering flexibility to growing businesses.
✔️ Quality Assurance Our ISO 9001:2015 certification and modern inspection systems ensure that every part meets rigorous standards. Larson’s team employs statistical process control (SPC) and root cause analysis to keep quality high and rework low.
Real-World Impact: Customer Success
Many of Larson’s customers come to us after facing high costs, quality issues, or delays with other suppliers. By redesigning the tooling, streamlining operations, and improving material yield, Larson routinely delivers:
- Up to 20 – 25% reductions in total part cost.
- Improved lead times
- Lower defect rates
- Long-term cost stability
- World class, on time delivery, we are currently celebrating 99.6% on time 2024/25
Whether it’s transitioning a complex assembly to a single stamped part or developing tooling for millions of parts per year, Larson has the technical knowledge and production capacity to deliver results.
Conclusion: Optimize Today for Savings Tomorrow
Minimizing the cost of metal stampings starts with smart design, efficient tooling, and a reliable manufacturing partner. While it may be tempting to focus solely on per-part pricing, the real savings come from a holistic view of the process—from concept through production.
Larson Tool & Stamping provides the engineering insight, production capabilities, and customer focus needed to reduce stamping costs without compromising performance or quality. By partnering with a team that’s committed to long-term value, you gain more than just a supplier—you gain a strategic advantage.
About Larson Tool & Stamping Company
Since its inception in 1920 in Attleboro, MA, Larson Tool & Stamping Company has been making a difference as a valued supplier of precision metal stampings and assemblies to hundreds of companies in the United States. Larson provides high-quality, cost-effective solutions with our wide range of capabilities that include forming, stamping, deep drawing, machining, assembly, brazing, coining, and water-jetting. Through significant investment in leading-edge manufacturing equipment and the loyal support from customers and co-workers, Larson perpetuates the commitment made by our founders to do whatever is necessary to meet and exceed customer expectations.
Ready to take the next step?
Contact Larson Tool & Stamping today to discuss your metal stamping needs and discover how we can help you reduce costs and increase quality across your product line.
