What is the most important rule in metal stamping part design?

The most important rule is to design the part around how sheet metal will actually be cut and formed, not only around the final CAD shape. A part should be manufacturable through a stable process sequence with realistic tolerances, practical radii, and features placed where the material can support them.

Why are holes near bends or edges risky in stamped parts?

Holes near bends or edges can distort during forming, break out at the edge, or become harder to hold position accurately. The risk increases when the surrounding material is limited or when later forming changes local shape.

How do tight radii affect stamping cost?

Very tight radii can increase crack risk, springback control difficulty, tool wear, and restrike requirements. Even when they are technically possible, they often raise die complexity and process tuning cost.

Why do stamped-part tolerances need to be realistic?

Different features respond differently to stamping. Flat pierced dimensions are usually easier to control than post-form geometry. If a drawing gives equally tight tolerances to all features, the supplier may need more tooling, more inspection, or more conservative pricing.

Does material choice change how a stamped part should be designed?

Yes. Material affects formability, springback, tool wear, surface sensitivity, and crack risk. A geometry that works well in low-carbon steel may not behave the same way in stainless steel or harder tempers.

Metal Stamping Parts Design Guide: DFM Rules Every Buyer and Engineer Should Know

By Liu Zhou / April 27, 2026

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