For decades, traditional metal blanking has been the backbone of automotive and industrial manufacturing. Mechanical blanking presses, stamping dies, and progressive tooling have delivered consistent results for high-volume production. But as manufacturing demands evolve, these time-tested methods are showing their limitations.

At BWD Technologies, we specialize in high-speed laser blanking that eliminates the constraints of traditional die-based processes. Our coil-fed laser systems represent the next generation of metal blanking technology.

Understanding Traditional Metal Blanking

Traditional Blanking relies on several established methods:

Mechanical Blanking Press Operations

• Uses physical dies to punch or shear material
• Requires custom tooling for each part geometry
• Excellent for high-volume, repetitive production

Stamping and Blanking with Progressive Dies

• Multiple operations performed in sequence
• High initial tooling investment
• Limited flexibility for design changes

Tool and Die Blanking Processes

• Compound die metal blanking for complex shapes
• Fine blanking services for precision applications
• Extensive die maintenance and storage requirements

Where Traditional Methods Fall Short

While these conventional sheet metal cutting approaches work well for established products, they create challenges in today’s fast-paced manufacturing environment:

• High Tooling Costs Custom dies can cost thousands of dollars and take weeks to fabricate.
• Design Inflexibility Any part modification requires new tooling or die changes.
• Long Setup Times Press blanking process changeovers can take hours.
• Material Limitations Advanced High-Strength Steels (AHSS) and aluminum alloys can cause accelerated die wear.

The BWD Advantage: Coil-Fed Laser Blanking

Our die-free blanking systems use high-power fiber lasers with linear motor propulsion to cut blanks directly from coil-fed material. This approach delivers:

• Zero Tooling Investment Eliminate costly mechanical dies entirely.
• Instant Design Changes Modify part geometry digitally without retooling.
• Superior Material Utilization Advanced nesting algorithms maximize yield from each coil.
• Consistent Quality Every blank meets exact specifications with minimal variation.

Industries Making the Switch

We’re seeing increased adoption across:

• Automotive OEMs and Tier 1 suppliers
• AHSS stampers looking for flexibility
• Aluminum mills seeking efficient processing
• Welded blank manufacturers
• Press hardening stampers

The Future Is Die-Free

Traditional metal blanking served manufacturing well, but today’s demands require more agility, efficiency, and precision than mechanical systems can provide. Laser blanking technology delivers all three without the constraints of conventional tooling.

Ready to explore the advantages of die-free blanking? Contact BWD Technologies today.