Schedule a 30-minute virtual session with our sheet metal applications engineers to review your design. This is your chance to address any questions you have about your project. Common topics for discussion include:
Our online sheet metal punching service provides high-quality, end-use products within days. Every project includes design for manufacturability (DFM) feedback and expert support. A variety of finishing options are available to meet your aesthetic needs.
Common applications of punching include:
Sheet metal punching is a manufacturing process that uses a punch press to apply force to a material, shaping it with specialized tools known as the punch and die. This method is used to create profiles, holes, and other formed features in sheet metal.
During the punching process, the punch presses the sheet metal against a die, shearing the material in a fast, repetitive motion to produce precise cutouts and features.
Common punched features include:
Sheet metal punching is a manufacturing process that uses a punch press to apply force to a material, shaping it with specialized tools known as the punch and die. This method is used to create profiles, holes, and other formed features in sheet metal.
During the punching process, the punch presses the sheet metal against a die, shearing the material in a fast, repetitive motion to produce precise cutouts and features.
Common punched features include:
Punching sheet metal components can be intricate, so to simplify integration into your next project, here are key manufacturability tips to keep in mind. Following these guidelines can help optimize costs while ensuring high-quality parts.
The maximum height for formed features should be 4 times the material thickness. The diameter of the tool station directly affects the recommended spacing between punch-formed features. For optimal spacing, we suggest using 50% of the tool station diameter.
| Tool Station Diameter | Space Required Between Features |
| 0.500 in. (12.7mm) | 0.250 in. (6.35mm) |
| 1.250 in. (31.75mm) | 0.625 in. (15.875mm) |
| 2.000 in. (50.8mm) | 1.000 in. (25.4mm) |
| 3.500 in. (88.9mm) | 1.750 in. (44.45mm) |
| 4.500 in. (101.6mm) | 2.250 in. (57.15mm) |
Punching offers both functionality and customization for sheet metal projects through various profile and form tooling shapes. Below is a reference for the common cutout and formed features we provide. If you need guidance on tool selection, whether in-house or custom, take advantage of a free 30-minute design review with our expert applications engineers.
Please note that custom punch tooling may increase your project’s cost and lead time. If cost is a key factor, we suggest considering in-house tooling options. During your design review, we’ll help determine which dimensions are most critical for your design (e.g., height, inside/outside diameter, open area, etc.) and offer the most suitable in-house tooling solution.
This tool is used to cut and raise a section of sheet metal, forming a hook or tab shape. Lance tabs are ideal for mechanical fastening, hanging, ventilation, clips, and stops.
If your design includes multiple small, simple bends, a single-hit punch tool may be the most cost-effective and efficient manufacturing method.
Single hit vs. progressive tooling: Single hit only
Bridge lances come in various shapes and sizes. While our in-house options are primarily single-bridge form-up tools, custom tooling can be made upon request. Unlike lance tabs, bridge lances use two points of contact with the sheet metal, creating a bridge-like feature.
Bridge lances are commonly used for decorative or functional purposes, such as clip attachments, airflow, cable pass-throughs, or fastening.
A bridge lance feature serves a similar purpose to TD (cable tie-mount) hardware available from PEM®.
Single hit vs. progressive tooling: Single hit only
Extrusions in sheet metal designs are made by pushing material through a die to form a raised shape. Common uses include electrical contact points, threaded holes, standoffs, and airflow or gas channels.
In production scenarios requiring higher volumes, extrusion and tapping can be an effective alternative to hardware insertion, leading to reduced part costs.
Single hit vs. progressive tooling: Single hit only
This tool partially cuts through the sheet metal, creating raised features or intentional material deformations. Half shears are useful for creating visual and physical markers for assembly processes, as parts can snap together or serve as alternatives to tabs or lances.
Single hit vs. progressive tooling: Single hit only
Perforations are used to create multiple holes or slots in a sheet metal design, leaving small amounts of material between the features. These designs are best achieved with punching, as heat from laser cutting can distort the material. A cluster tool is often used to punch several holes or slots simultaneously. A common example is the in-house hex pattern tool.
When designing perforations, ensure the size of the hole or feature is equal to or greater than the material thickness. Also, consider making the spacing between features the same thickness as the material.
Perforations are ideal for applications such as ventilation, filtration, drainage, or for decorative and weight-reduction purposes.
Single hit vs. progressive tooling: Single hit only
Louver tools create slotted openings, often used in electrical enclosures or panels to allow for ventilation. These tools help manage heat and airflow, especially in electronics enclosures.
Single hit vs. progressive tooling: Can be used with both single hit and progressive tooling
Ribs are raised, oblong shapes that enhance the strength and rigidity of a design without adding excessive weight. In electronics enclosures, they aid thermal management and overall structural integrity. Ribs can also create gaps to separate components.
Single hit vs. progressive tooling: Progressive only
Emboss or dimple tools provide functional and aesthetic improvements to sheet metal designs. These features can serve as mounting points, spacers, or decorative elements. Common shapes for embosses include round, oblong, and rectangular. Embosses can also conceal hardware heads without sacrificing structural integrity.
Single hit vs. progressive tooling: Single hit only
Sheet metal parts with punched features can be used as standalone components, but they are often part of a larger assembly, sub-assembly, or weldment.
We provide the following assembly services to ensure that your project is ready for immediate use upon arrival:
Lead time: Assembly lead time typically adds 1-3 days, depending on the number of components.
Beyond customizing features and geometry, our finishing services provide additional options to meet your aesthetic requirements for punched parts and assemblies. Available finishing options include:
For more information, please visit our finishing options page.
Lead time: Most finishing options add 1-2 days to the overall lead time. Detailed information is available on our finishing options page.
