Worthy Hardware, a leader in precision stamping and sheet metal fabrication, brings a wealth of experience and expertise in manufacturing. Understanding the proper stamping process is vital in our industry, where precision, efficiency, and cost-effectiveness are paramount. 

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This article will delve into Progressive Die, Compound Die, and Transfer Die Stamping. Each of these methods has its unique advantages and limitations, which can be crucial in determining the success of a manufacturing project. By understanding these differences, manufacturers can make informed decisions to optimize their production processes.

Keeping up with the latest trends and technologies in stamping is essential for manufacturers. The choice of the stamping process can be the difference between success and failure in a project. In the following sections, we'll explore each method in detail, helping you understand which process best suits your manufacturing needs.

Understanding the Basics

What is Stamping? 

Stamping in manufacturing refers to shaping metal by pressing it into a die. This technique is a cornerstone of the metal fabrication industry, playing a crucial role in producing a wide range of products. 

Stamping's history dates back to the early days of industrialization, evolving from simple manual processes to complex, automated systems. Its significance lies in its ability to mass-produce uniform, high-quality components quickly and efficiently, making it indispensable in today's manufacturing landscape.

Types of Stamping Dies 

The world of stamping is diverse, with several types of dies used to shape metal differently. The three primary types are Progressive, Compound, and Transfer Dies. Each type offers distinct advantages and is suited for specific applications. 

Progressive dies are used for high-volume production, creating parts in several stages. Compound dies combine multiple operations into a single stroke, making them efficient for simpler parts. Transfer dies are versatile and suitable for larger, more complex components. 

Progressive Die Stamping

Definition and Process 

Progressive Die Stamping is a fabrication process where a metal strip is fed through a series of stations, each performing a different operation until the final component is produced. 

Imagine it like a conveyor belt system in a factory, where each station adds a new feature to the part, culminating in a complete, precisely crafted product. 

This process is particularly advantageous for high-volume production runs, as it combines speed with consistency.

Advantages of Progressive Die Stamping

The foremost advantage of Progressive Die Stamping is its high-speed production capability. It's like a well-oiled machine, churning out parts rapidly and efficiently. 

This method is also cost-effective for large volumes, as the per-part cost decreases significantly with higher production numbers. 

Moreover, it ensures consistent quality in each part, critical in applications where precision is non-negotiable. The ability to include various operations like punching, coining, bending, and several others in a single process also streamlines the manufacturing timeline.

Disadvantages and Limitations 

However, Progressive Die Stamping has its drawbacks. The initial tooling cost can be high, which might be a significant upfront investment for some projects. This process is best suited for large production runs where the high initial cost can be amortized over many parts. 

Additionally, there are limitations in the complexity of parts that can be produced. Exceptionally intricate parts require additional operations or different stamping methods, potentially complicating manufacturing.

Compound Die Stamping

Definition and Process 

Compound Die Stamping differs from Progressive Die Stamping in completing multiple operations - such as cutting and forming - in a single stroke. This method is akin to a chef performing several cutting tasks in one swift motion. 

It's particularly effective for producing flat parts, where multiple features must be added simultaneously. This single-stroke approach ensures high precision and alignment, making it ideal for parts with paramount dimensional accuracy.

Advantages of Compound Die Stamping 

The primary advantage of Compound Die Stamping is its precision. Since multiple operations are executed in a single stroke, the risk of misalignment between processes is minimized, resulting in highly accurate parts. 

This method is also efficient for producing flat components, as it reduces the number of hits needed compared to other methods, thereby speeding up production. 

Additionally, Compound Die Stamping tends to generate less scrap material, contributing to cost savings and environmental sustainability.

Disadvantages and Limitations 

The limitations of Compound Die Stamping include its lower production speed than Progressive Die Stamping, as it's generally used for more detailed and precise work rather than high-speed mass production. 

Moreover, there are better methods for complex parts that require multiple bending or forming operations. The complexity and depth of parts that can be produced are limited, which means this method is best suited for simpler, flatter components.

Transfer Die Stamping

Definition and Process 

Transfer Die Stamping is a process where individual parts are mechanically or manually transferred from one stamping station to the next. This method is like an assembly line where each station contributes a specific aspect to the final product. It is ideal for larger, more complex parts that require multiple sequential operations. 

Transfer Die Stamping allows more flexibility in part handling and orientation, making it suitable for intricate designs and shapes.

Advantages of Transfer Die Stamping 

The key advantage of Transfer Die Stamping lies in its flexibility to handle complex parts. It's like a skilled artisan capable of crafting intricate designs. This method can incorporate various operations such as punching, bending, drawing, and trimming in a single production cycle. 

It's also suitable for short and long production runs, providing versatility in manufacturing scale. 

Additionally, Transfer Die Stamping allows for the production of more significant parts, which might not be feasible with Progressive or Compound Dies.

Disadvantages and Limitations 

However, Transfer Die Stamping comes with its set of challenges. The operational costs can be higher due to the complexity of the setup and the need for skilled labor for maintenance and operation. 

The setup time for each run can be longer, especially for more intricate parts, which might affect overall production timelines. 

Additionally, this method requires a higher degree of precision in die design and maintenance to ensure consistent quality and efficient operation, which can add to the complexity and cost of the process.

Comparative Analysis

Comparing the Processes 

Comparing Progressive Die, Compound Die, and Transfer Die Stamping is essential when choosing the proper stamping process. Each method has its unique strengths and is suited to different manufacturing requirements.

Speed and Efficiency

Progressive Die Stamping stands out for its high-speed production, making it ideal for large-volume runs. On the other hand, Compound Die Stamping, while precise, is slower and more suited for simpler, flat parts. Transfer Die Stamping offers flexibility but generally has a slower setup and production speed than Progressive Die Stamping.

Cost Considerations

The initial tooling cost for Progressive Die Stamping can be high, but it becomes cost-effective in large-volume production due to lower per-part costs. Compound Die Stamping is efficient in material usage, thus reducing scrap and cost, but it might not be economical for complex parts. Transfer Die Stamping involves higher operational costs, particularly for intricate designs and short runs.

Complexity and Part Design

 Transfer Die Stamping is usually the preferred method for complex part designs due to its flexibility. Progressive die stamping is less suited for challenging parts but is excellent for simpler designs produced in large quantities. Compound Die Stamping is ideal for creating high-precision flat parts but is limited in handling complex shapes and designs.

Volume Suitability

Progressive Die Stamping is the go-to for high-volume production. Compound Die Stamping is more suited for smaller runs where precision is critical. Transfer Die Stamping offers versatility for short and long production runs, but its cost-effectiveness varies based on the complexity and volume of the parts.

Here is a table-based comparison of the three stamping processes based on the discussed characteristics:

Characteristic Progressive Die Stamping Compound Die Stamping Transfer Die Stamping Speed and Efficiency High-speed production, ideal for large volumes Slower, suited for simpler, flat parts Flexible, slower setup and production speed Cost Considerations High initial tooling cost, cost-effective in large volumes Efficient material usage, reducing scrap and cost Higher operational costs, especially for intricate designs Complexity and Part Design Less suited for complex parts, excellent for simpler designs Ideal for flat parts with high precision, limited in complex shapes Preferred for complex designs, requires precision in die design Volume Suitability Best for high-volume production Suited for smaller runs where precision is key Versatile for both short and long runs, cost varies by complexity and volume

Choosing the Right Process for Your Needs

Part Design: The complexity and specifications of the part you intend to produce play a crucial role in determining the stamping process. 

Compound Die Stamping may be the best choice for simpler, flatter parts due to its precision and efficiency. 

However, for more complex parts, particularly those requiring multiple, sequential operations, Transfer Die Stamping might be more suitable. 

Progressive Die Stamping is ideal for less complex parts that need to be produced in large quantities.

Volume Requirements: The number of parts needed can significantly impact the choice of stamping process. 

Progressive Die Stamping is generally the most cost-effective and efficient option for high-volume production runs.

In contrast, for smaller runs or prototypes where precision is crucial, Compound Die Stamping might be more appropriate. 

Transfer Die Stamping can be versatile and suitable for both short and long runs, depending on the complexity of the parts.

Budget Constraints: Budget is always a critical factor in manufacturing. 

Progressive Die Stamping has a higher initial tooling cost and can be more economical in the long run for large-scale production due to lower per-part costs. 

Compound Die Stamping can be more affordable for smaller runs but not cost-effective for larger volumes or complex parts. 

Transfer Die Stamping generally involves higher operational costs, which must be considered, especially for intricate designs and short runs.

Case Studies or Examples:

Example 1: Automotive Industry - A manufacturer requires a large volume of metal brackets with a simple design. Progressive Die Stamping was chosen for its ability to rapidly produce these parts at a lower cost per unit, making it an ideal choice for this high-volume requirement.

Example 2: Electronics Industry - For the production of intricate components used in smartphones, Transfer Die Stamping was employed. The complexity of the parts, along with the need for precise tolerances and various operations, made this method the most suitable.

If you are looking for more details, kindly visit progressive die design.

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Example 3: Aerospace Industry - Compound Die Stamping was used for producing high-precision, flat components in smaller quantities for aerospace applications. The need for extreme precision and quality, coupled with lower volume requirements, made Compound Die Stamping the preferred choice.

Conclusion

At Worthy Hardware, we pride ourselves on providing custom solutions for all OEM precision stamping parts. Our expertise in Progressive Die, Compound Die, and Transfer Die Stamping ensures that we can guide you in selecting the most efficient and cost-effective method for your project.

We encourage you to reach out to us with your specific project requirements. Let's work together to determine the best stamping process for your needs, ensuring quality, efficiency, and cost-effectiveness in your manufacturing endeavor

Progressive Die - The Advanced Level of Metal Stamping

What Is Progressive Die Stamping?

What Is A Progressive Die?

A progressive die is a complex, multi-station tool used in progressive die stamping. It is designed to transform a flat metal strip into intricate parts. As the strip is fed into the stamping press, it continuously moves through various stations of the tool. Typically, each station performs a distinct operation—such as blanking, chamfering, piercing, bending, rounding, or even deep drawing. With each press stroke, multiple operations occur simultaneously, making the progressive die highly efficient. This process is analogous to an assembly line, where each station focuses on a single task, but collectively, they transform the strip into a finished product, enhancing overall efficiency.

What Is the Difference Between a Progressive Die and Other Metal Stamping Dies?

1. A simple die features just one station and performs a single operation per stroke, such as cutting, bending, or piercing, making it a single-purpose tool. 

2. It is suitable for parts of low complexity. While multiple simple dies can be used sequentially to shape a part, using too many can significantly reduce efficiency. 

3. It is recommended for low-volume production and are particularly effective for straightforward designs. They are generally less expensive and simpler to manufacture compared to compound or multi-station dies.

A progressive die stands out from a simple die in several key ways: 

1. It incorporates multiple stations, each designed to perform distinct operations. This setup allows for the production of more complex parts with high precision and efficiency. In contrast, simple dies execute a single operation per press stroke. Progressive dies, however, can perform multiple operations simultaneously during each stroke, facilitated by an advanced material feeding system.

2. Progressive die stamping is particularly advantageous for projects that involve complex designs and require large quantities or mass production.

What Is the Difference Between Progressive Die and Compound Dies?

1. A compound die features only one station but performs multiple cutting operations. If this die also includes other operations like bending, drawing, and chamfering in a single station, it is referred to as a combination die. Despite being a multi-purpose tool, its application is quite limited due to the restricted number of operations it can perform, making progressive stamping generally more efficient for most designs.
2. It is typically used for producing low-complexity, flat parts such as washers.
3. It requires a high punch force to operate.
4. It maintains a high production rate.

A progressive die differs from a compound die on the following aspects:

1. It consists of multiple stations, each performing different operations during the same stroke, achieving similar production efficiency to compound dies but with advantages like shorter testing and tool setup times, as well as reduced maintenance and repair requirements. 

2. Progressive dies can create more complex shapes due to the numerous stations and operations that can be incorporated within the same tool. 

3. Generally, progressive dies operate faster than compound dies by reducing material handling costs, thus making them more suitable for mass production. 

4. Operations in a progressive die are carried out at different stations; for instance, while a compound die might perform blanking and piercing in one station, a progressive die would handle these tasks at separate stations, improving both efficiency and the quality of the final product.

What Is the Difference Between Progressive Die and Transfer Die?

Transfer dies share similarities with progressive dies but are distinct in several ways: 

1. Transfer dies are multi-stage stamping tools; however, unlike in progressive dies where a part advances progressively through a series of stations while remaining connected to a strip, in transfer dies, the part (or blank) moves from one station to another between each stroke. 
2. These dies support intricate designs and are particularly suitable for deep drawing operations. 
3. They require a complex transfer and lifting mechanism to function, which can complicate their design.

On the other hand, progressive dies differ from transfer dies in these critical areas: 

1. In progressive dies, the part remains attached to a strip until the final operation, whereas in transfer dies, the blank is cut out during the first operation. This difference can lead to more scrap material in progressive dies due to the space needed for the strip, but it also allows for quicker operations with less movement required between strokes. 
2. Progressive dies have some limitations with deep drawing operations, which transfer dies can better accommodate, as they allow extensive drawing depending on the raw material's limits. Layana’s engineering team is available to help determine whether a progressive or a transfer die would be more effective for your mass-production needs.

Comparison Between Tooling Dies: Simple dies vs. Compound dies vs. Progressive dies vs. Transfer Dies

FeatureSimple DieCompound Die or Combination DieProgressive DieTransfer Die Operations Single operation Multiple operations (single stroke). Very limited to design. Multiple operations (sequence). Slightly limited to design. Some complex drawing operations would require a transfer die Multiple operations (transfer between stations). Any operation process is possible. Stations One station One station Multiple stations Multiple stations Complexity Low Low to medium High complexity High complexity Mold testing and set up Easy Difficult Moderate. Modules reduce complexity and increase set up efficiency. Usually easier than progressive, but requires transfer and lifting devices that are also complex to design. Efficiency Very low Low Very high High. Slower than progressive given the required transfer operations. Cost Low tooling cost, high part unit cost Medium tooling cost, medium part unit cost High tooling cost, very low part unit cost Normally higher tooling and unit cost than progressive Production volume Low volume Medium to high volume High volume (appropriate for mass production) High volume, (appropriate for mass production) Suitability Simple parts Simple parts Complex parts Larger and/or concave parts, complex parts Material utilization rate Moderate to high Moderate to high Moderate. The need for pilots and carriers can reduce material utilization. A good design can highly reduce the scrap produced. Moderate to high Blanking operation 1 stroke 1 stroke The last operation The first operation   

Not Sure About Which Type of Stamping Die Is Right for Your Project?

Layana Company has solid R&D teams that can provide you the best solution to make your products. We have more than 4 decades of experience designing multi-station dies and will help you address which type of multi-station die will fit your project and proficiently design and develop the required tooling and equipment for efficient and precise manufacturing. We are IATF , ISO and ISO certified global leading OEMs manufacturer that specializes not only in metal stamping but also plastic injection, insert molding, and assembly which positioned Layana as a key ally in executing highly complex projects.

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Why Choose Layana?

1. Our comprehensive services, including stamping, plastic injection (featuring insert molding), and assembly, position us as a pivotal collaborator for your most challenging projects. With Layana, you gain access to an integrated quality management system that aligns with the highest industry standards, offering total quality management throughout all manufacturing stages.
2. Engineering Excellence and ESG Commitment: Our skilled engineering team is ready to assist you in designing and developing progressive dies that not only meet but exceed your project's demands. We focus on maximizing production efficiency, ensuring your project's success. By partnering with Layana, you also advance your Environmental, Social, and Governance (ESG) goals. Our Green Factory certification is a testament to our commitment to sustainable, ethical, and environmentally responsible manufacturing processes.  

Layana's Progressive Die Capabilities

Layana has a core team of toolmakers, some with 40 years of experience from simple dies to progressive dies, and toolings are mostly made in-house.

Category

Capability

The Maximum Size of a Tooling

Up to 2,500mm*1,000mm*550mm

The Maximum Weight of a Tooling Up to 1,200kg

Range of Material Thickness

0.02mm~6mm

Tolerance Range

Up to ±0.01mm

Productivity/Month

10 sets of dies

Range of Stamping Machine

From 25T to 300T

What Are the Advantages of Progressive Dies?

• Increased Efficiency: Progressive dies excel in their ability to perform multiple operations in a single pass through the press. This multi-tasking capability significantly speeds up production, enabling the manufacture of thousands of parts per hour. This efficiency is critical in high-volume production environments where time and speed are of the essence.

• Cost-Effectiveness: Although the initial setup cost for progressive dies can be higher, the long-term savings are substantial. The continuous nature of the process reduces labor costs and increases throughput, making it a cost-effective solution for large runs. Moreover, the precision of progressive dies minimizes material waste, further driving down costs.

• Enhanced Precision and Consistency: Progressive dies are renowned for their ability to produce parts with high precision and uniformity. Each station within the die is designed to perform a specific operation precisely, ensuring that every part produced is consistent with the next. This is particularly advantageous for industries requiring tight tolerances and high-quality standards, such as automotive and aerospace.

• Reduced Labor Requirements: Since the progressive die stamping process is highly automated, it requires fewer operators. This not only reduces labor costs but also decreases the potential for human error, enhancing the overall quality of the production.

• Versatility: Progressive dies can handle a variety of materials and can be designed to perform a wide range of operations—from cutting and punching to bending and coining. This versatility makes them suitable for producing complex components used in various industries.

• Scalability: Progressive dies are scalable to meet increasing production demands. Once the die is designed and created, scaling up production is a matter of running the die for longer periods, making it easy to respond to higher demand without significant additional costs.

• Improved Safety: The automated nature of progressive die stamping reduces the chance of operator injury, which is especially important in fast-moving production environments. The machines are designed with safety in mind, limiting operator interaction with the press during operation.

• Longevity: Progressive dies are built to last. With proper maintenance, they can operate for millions of cycles, making them a durable investment for continuous, long-term use.

What Are the Disadvantages of Progressive Dies?

• Not suitable for low quantities: Progressive dies require high tooling design, development, and manufacturing cost, which are easily amortizable for large quantities, but for very low quantities other metal forming methods might be considered.

• Not suitable for all designs: If the parts cannot be formed from metal blanks, because the part is too big, too thick, has undercuts, very sharp angles and tight bends, or other internal features, stamping won't be able to achieve them. Other metal forming methods such as CNC machining, casting, forging, rolling, or extrusion might be considered. Layana engineers can help to evaluate the manufacturability of your design and propose the best solution for you.

• Not suitable for prototype development: giving the upfront tooling cost, and die design and manufacturing requirements, the need of supplementary forming methods might be considered for making prototypes, such as 3D printing or CNC machining.

• Strength requirements: for some applications where exceptional strength is required, other forming methods that imply grain structure reinforcement might be required, such as forging.

• Not suitable for designs with some specific deep drawn requirements: Even progressive dies allow deep draw, for some designs or if the drawing is too deep, transfer dies might be considered.

• The die design and manufacturing complexity: Progressive dies are very complex and require a professional, dedicated engineering team with many years of experience. Layana Company has an engineering team, with engineers with decades of experience in the design and fabrication of progressive dies.

Elements Required for Progressive Die Stamping

To produce parts through progressive die stamping, several critical components are necessary:

1. A Progressive Die: Designing and producing high-quality, durable, and reliable progressive dies is a capability not all companies possess. Layana Company, however, boasts decades of experience in crafting progressive dies used by world-class OEM manufacturers across various industries, including Automotive, Electronics, Medical, and Aerospace.
   
   
2. A Stamping Press: Layana houses a range of stamping presses with capacities from 25T to 300T. These presses enable us to offer metal stamping mass production services to a global clientele, primarily using progressive dies that are designed and developed in-house.
   
   
3. A Feeding System: This is a crucial component in progressive die stamping. The feeding system must provide smooth and consistent material flow, ensuring precise positioning and speed across the different stations of the progressive die. Essential features of this system include:
     1.    Uncoiling and Flattening System: Necessary for preparing the raw material for entry into the progressive die, this system unrolls and flattens the metal strip.
     2.    Collector System: Positioned at the end of the feeding line, this system gathers the leftover metal strip material after the final blanking operation. The collected scrap can then be re-coiled and recycled.
   
   
4. Raw Material: Typically, the raw material used in progressive die stamping is a metal coil that is unrolled, flattened, and fed into the stamping press. The choice of material is critical and depends on the design and engineering requirements of the part, considering factors such as ductility, hardness, electrical conductivity, and cost. Common materials include stainless and carbon steel, ferrous alloys, aluminum, brass, bronze, copper, beryllium copper, and titanium.
   
   
5. Skilled Operators: Progressive die stamping is a sophisticated metal forming technique that demands well-trained and experienced operators. These professionals are essential for minimizing downtime, optimizing production efficiency, ensuring quality, maintaining safety, and performing periodic maintenance. Layana Company ensures that all operators are highly skilled, bringing years of industry experience and a commitment to continuous improvement. Notably, Layana was recognized with the Green Factory label in , affirming its commitment to the highest ethical standards and working conditions for its operators.
   
   
6. Quality Management: A dedicated quality lab and a quality assurance department are crucial to control the quality of stamped parts and ensure compliance with the stringent protocols and standards required in industries like automotive. Layana Company not only offers tooling design and progressive die stamping production services but also implements comprehensive quality management throughout the manufacturing process, meeting the rigorous standards of the electronics and automotive industries.
   
   
7. Professional Engineering Team: The success in metal stamping significantly depends on the quality of the engineering team. Layana's engineers are adept at designing high-quality and precise dies, integrating the latest technology, and providing solutions for challenges that arise during the design, development, and production stages. With four decades of experience, the Layana engineering team has established a reputation for designing progressive tooling that meets world-class standards and achieves efficient, sustainable production for parts used in leading global OEM companies.

Progressive Die Stamping Process and Key Components of A Progressive Die

Here is an overview of the process and the essential operations involved in progressive die stamping:

Feeding System and Pilot Holes: The process begins with the feeding system delivering the flattened metal strip into the progressive die within the press. Accurate positioning of the strip is crucial for precision in subsequent operations. To achieve this, pilot holes are initially pierced in the strip at the first station. These holes guide the strip precisely through subsequent stations, ensuring it is perfectly aligned for each stroke of the machine.

Operations in Progressive Die Stamping:

1. Piercing or Punching: This involves creating holes in the metal strip.
2. Blanking: This process cuts out pieces of the raw material to shape the final part.
3. Coining: This operation uses pressure to create specific surfaces or features on the part.
4. Chamfering: This involves cutting the edges of a part at a 45-degree angle to remove sharp 90-degree edges.
5. Bending: This process transforms a flat material into a three-dimensional shape.
6. Embossing: This technique creates raised or recessed designs on the metal surface, often for aesthetic purposes.
7. Drawing: This is the process of stretching sheet metal into a U-shaped cavity to form the part.
8. Deep Drawing: A specialized form of drawing used when the height of the part is equal to or greater than half its diameter.

Some of these processes can be observed in the diagram below, with a metal strip resulting from different progressive die operations:

Progressive dies differ from other stamping dies of less complexity on the use of modules to increase efficiency of design, maintenance and installation efficiency, the level of complexity because of the multi-station nature, the use of pilots to alight the metal strip, or the stripper plate so that the scrap will not be raised with the male die.

Below there is a diagram with some of the different parts that are common to most of the progressive dies, but keep in mind that the components observed in a die might vary between dies given its complexity, the different design possibilities, the almost infinite possibility of shapes that can be created, the nature of project, among other factors.

The Applications of the Progressive Dies

Progressive dies enable the stamping of a great variety of parts and components that will be later used as finish parts, assembled in other products, or embedded in plastic using plastic insert molding techniques and creating more complex parts. Metal stamping, and specifically the progressive die stamping, is widely used in the automotive, biking, aerospace, medical equipment, optical, electronics industries, or even it can be used to make cutlery products.

Products such as home appliances or electronics components commonly used progressive die stamped components, for instance the springs, lead frames, connectors, contactors, covers, sensors terminals, pins and contacts, cages or even the USB ports. Many components from the PCBs are also made using progressive die stamping or microstamping.

For the automotive industry, apart from the terminals and connectors previously mentioned, and many times inserted into plastic using insert molding, one of the Layana’s specialties, many kinds of brackets, washers, spacers, plates, clutches, valves retainers, protective housing or shields, fasteners, or even trim and cosmetic parts are manufactured massively, securely, and effectively thanks to the progressive dies.

Apart from the mentioned industries, the possibilities are almost infinite and recently, we have seen the incorporation of progressive die stamped parts into new products such as drones, solar panels, electric car chargers, etc.

Contact us to discuss your requirements of Cross Car Beam Assembly. Our experienced sales team can help you identify the options that best suit your needs.