Project Background & Customer Challenge
Recently, a customer designed a 0.8mm thin stainless steel component. During the initial prototyping phase, they utilized laser cutting to fabricate samples and verify dimensional functionality. Once the design was validated, the customer approached Apporo to evaluate building a stamping mold for mass production, aiming to achieve faster production speeds and more competitive unit pricing compare to laser cutting.
The part geometry was simple and requiring only blanking (cutting to shape) with no bending involved. However, the customer had strong concerned regarding sharp edges and burrs along the sheared cutouts.
Shearing Characteristics of Thin Sheet Metal
As discussed in our previous case study (Fine Blanking vs. Conventional Stamping), thick metal sheets sheared during conventional stamping typically exhibit a significant roll-over radius on the cut edge alongside sharp burrs on the fracture zone. When transitioning to thin sheet metal (such as 0.8mm stainless steel), the roll-over radius becomes much less; however, the cut edge still remains razor-sharp with microscopic burrs.
Left untreated, these sharp edges pose safety hazards to assembly operators and can easily damage adjacent wires, hoses, or surrounding components in the final assembly.
Deburring and Surface Finishing Solutions
To eliminate edge hazards and achieve the desired cosmetic texture, Apporo offered three surface finishing solutions:
| Finishing Method | Media Type | Surface Appearance | Deburring Capability & Features | Ideal Application |
| Ceramic Vibratory Finishing | Ceramic / Stone Media | Matte / Grey Finish | High stock removal rate; excellent deburring performance. | Internal structural parts where function precedes appearance. |
| Steel Ball Vibratory Finishing | Steel Balls | Smooth & Glossy | Combines deburring with surface burnishing/smoothing. | Cosmetic exterior parts requiring a clean, polished look. |
| Magnetic Pin Tumbling | Stainless Steel Magnetic Pins | Bright & Polished | Gentle deburring action; reaches intricate cutouts and micro-holes. | Precision exterior/cosmetic components with delicate features. |
Compare varied deburring and polishing options to find your desired finish.
From initial tooling design and mass stamping to selecting the optimal post-processing method, Apporo provides comprehensive manufacturing solutions tailored to our clients' functional and aesthetic requirements. If you have upcoming stamping projects or need guidance on surface finishing options, contact our engineering team today to discuss your ideas!