Mechanical/Servo Punching

Mechanical/servo punching forms holes and cutouts in sheet metal with a press-driven punch and die, delivering high speed and repeatability.

Overview

Mechanical/servo punching (punch press) uses matched punch-and-die tooling in a mechanical flywheel or servo-driven press to shear holes, slots, and simple profiles in sheet metal. It’s fast, consistent, and cost-effective for repeat features, especially when standard tooling can be used and the part fits within the press tonnage and bed size.

Choose it for medium to high volumes, tight cycle-time targets, and parts dominated by piercings and simple blanking. Servo presses add control over ram motion (dwell, stroke profiles) that can improve forming consistency and reduce shock and noise.

Tradeoffs: geometry is limited by available tooling and press setup; complex contours often require nibbling or secondary operations. Expect burrs and potential distortion near features, plus the need to manage slug pulling and part marking. Tooling, setup, and die maintenance drive cost, so design around standard sizes and consistent feature spacing.

Common Materials

  • Cold Rolled Steel
  • Stainless Steel 304
  • Aluminum 5052
  • Galvanized Steel
  • Copper C110

Tolerances

±0.005"

Applications

  • Electrical enclosure panels
  • HVAC brackets and hangers
  • Chassis and rack-mount panels
  • Appliance mounting plates
  • Perforated guards and screens
  • EMI/RFI shielding panels

When to Choose Mechanical/Servo Punching

Pick mechanical/servo punching when your sheet metal part is mostly holes, slots, and simple edge profiles that repeat across many parts. It fits best for medium to high volumes where fast stroke rates and consistent feature quality matter and where standard tool sizes can be used.

vs CNC Turret Punching

Choose mechanical/servo punching when you have a stable design, high repeat volumes, and a short list of features that justify dedicated setup and optimized stroke rates. It can deliver lower cost per part and higher throughput when you’re not relying on frequent tool changes or highly varied feature sets.

vs Laser Cutting

Choose mechanical/servo punching when features are dominated by standard holes/slots, you need very fast cycle times, or you want formed features like louvers/embosses that are difficult or slow to laser. Punching can also reduce heat effects and improve productivity on large perforation patterns.

vs Waterjet Cutting

Choose mechanical/servo punching when you need production throughput and low cost per hole/cutout in sheet thicknesses suited to punching. It’s better for repetitive pierce patterns where waterjet time would dominate cost.

vs CNC Machining

Choose mechanical/servo punching when the part is a flat sheet component and the critical work is piercings/cutouts rather than 3D features. Punching hits hole patterns quickly without the long cycle times and workholding complexity typical of milling sheet parts.

Design Considerations

  • Use standard hole and slot sizes that match common punch tooling to avoid custom tools and long lead times
  • Keep minimum hole diameter at or above material thickness when possible to reduce punch breakage and burr issues
  • Maintain adequate edge distance and feature-to-feature spacing (often ≥1x material thickness) to prevent distortion and tearing
  • Call out burr direction/allowable burr height and any deburring requirements so quoting is consistent
  • Avoid sharp internal corners unless you accept nibbling, a larger corner radius, or a secondary operation
  • Provide flat pattern with bend lines and critical datums; note grain direction if it matters for forming or cosmetics