Technological principle
Stamping process: Using the pressure of the punching machine, the metal plate is plastic deformed at room temperature through the mold, so that the plate forms a badge with the same shape as the mold under the action of the mold, mainly shear, bending, stretching and other operations on the metal plate.
Casting process: Liquid metal (such as copper, zinc alloy, etc.) is poured into the pre-made mold cavity, and the liquid metal is cooled and solidified to form a badge consistent with the shape of the mold cavity.
Production process
Stamping process: Design badge drawings → Make molds → Select and process sheet metal → stamping → punching → Polishing → Welding parts → Electroplating → Coloring (optional) → Packaging.
Casting process: Design badge drawings → Make molds (generally sand molds, die casting molds, etc.) → melt metal materials → Pour liquid metal into molds → cooling solidification → Stripping → Clean burrs and flash → Surface treatment (such as polishing, plating, coloring, etc.) → Packaging.
Badge features
Appearance details: The badge made by the stamping process has clear lines and neat edges, but the ability to express complex three-dimensional patterns or fine details is relatively limited; The casting process is capable of producing very complex shapes and fine details, including patterns with rich layers and dimensions, such as some badges with intricate relief effects.
Surface texture: The stamped badge surface is usually smooth, strong metal texture; The surface of the cast badge may have some small bumps or textures, especially when using some special casting processes or mold surface treatments, but a higher finish can also be achieved through subsequent polishing and other treatments.
Dimensional accuracy: The stamping process can achieve high dimensional accuracy, especially for the simple shape of the badge, to ensure the accuracy and consistency of the size; Although the casting process can also control the dimensional accuracy, because the liquid metal will shrink during the cooling process, for some high-precision requirements of the size, may need to be adjusted in the subsequent processing.
Material selection
Stamping process: suitable for a variety of metal materials with certain ductility and hardness, such as copper, iron, aluminum and its alloys, commonly used brass plate, stainless steel plate and so on. Generally, the material is required to have good stamping performance to ensure that there will be no cracks, cracks and other defects in the stamping process.
Casting process: Almost all metal materials can be used for casting, including some metals with higher melting points. In badge production, commonly used zinc alloy, aluminum alloy, copper alloy and so on. For some materials that are difficult to be formed by stamping, the casting process has greater advantages.
Production cost
Mold cost: The mold of the stamping process is usually made of steel and other materials, and the processing accuracy is high, and the mold production cost is relatively high, especially for the badge mold of complex shape; The cost of the mold of the casting process varies according to different casting methods, such as the cost of sand mold is relatively low, but for high-precision molds such as die casting, the cost is also high. However, in general, when making badges with the same level of complexity, the stamping die cost may be higher.
Material cost: stamping process due to the use of metal sheet, the material utilization rate is relatively low, especially for the complex shape of the badge, will produce more corner waste; The casting process can be based on the actual shape and size of the badge for the pouring of liquid metal, the material utilization rate is relatively high, but if you take into account some factors such as the scrap rate in the casting process, the material cost may also increase.
Processing cost: The stamping process in the molding process is fast, high production efficiency, for mass production, the unit processing cost is relatively low; In the casting process, the process of pouring and cooling of liquid metal is relatively time-consuming, the production efficiency is relatively low, and the unit processing cost is higher in small batch production, but in mass production, the cost will gradually decrease due to the versatility of the mold and other factors.
Production efficiency
Stamping process: The stamping machine can quickly carry out the stamping operation, which can be completed several times per minute, and the production efficiency is very high for the simple shape of the badge, which is suitable for mass production.
Casting process: The overall production cycle is relatively long, especially for some casting badges that require fine processing and complex processes. However, when using some advanced casting equipment and processes, production efficiency can also be improved to a certain extent.
Post time: Jan-13-2025