How to Choose the Right Metal Forming Process for Your Automotive Parts?

Selecting the wrong metal forming method¹ can lead to delayed launches, ballooning costs, or even rejected parts.
Here’s how to get it right the first time—just like we help OEMs and Tier 1s do every day.

Whether you’re developing a prototype bracket or planning a 100,000-piece production run, choosing the right forming process² is critical to hitting your performance, timing, and cost targets.

What Should You Consider First?

Before diving into stamping, casting, or CNC, ask yourself:

What does this part actually need to do—and how many do I need?

Here are five questions I walk through with customers every day:

Quick Guide: Which Process Fits Your Part?

You don’t need to guess. Here’s a shortcut decision matrix based on what your part needs:

When to Choose CNC Machining

CNC machining³ is your best bet when precision matters—and volumes are low to mid-range.

It’s fully digital, ideal for early prototyping⁴, and supports quick design iterations. Most importantly, it doesn’t require tooling—cutting time and risk.

Use Case: Engine Test Fixtures

A Tier 1 client needed test fixtures for an EV drivetrain. We used CNC to rapidly deliver 10 functional units with tolerances under ±0.01mm. No tooling cost, full design freedom.

When Metal Stamping Is the Smart Move

If you’re producing thousands—or hundreds of thousands—of simple parts, nothing beats stamping.

Once the dies are built, the speed and repeatability are unmatched. It’s the automotive industry⁵‘s backbone for clips, brackets, and reinforcement plates.

Use Case: Seat Brackets

We helped an OEM transition a stamped seat bracket from overseas to local supply. The result? 3-week lead times, consistent flatness, and 20% cost savings through progressive die optimization.

What About Die Casting and Extrusion?

Each has its niche—but only if your part fits the profile.

Die Casting (Aluminum or Zinc)

Best for complex 3D shapes like housings or connectors.

• Great dimensional stability
• Cost-effective for high volumes
• Only for non-ferrous metals

Aluminum Extrusion

Ideal for straight, symmetrical parts like rails or heat sinks.

• Consistent cross-sections
• Fast production
• Limited geometry options

CNC + Stamping: The Best of Both Worlds

Most efficient teams don’t pick just one—they sequence smart.

We call this the Prototype → Validate → Stamp strategy:

1. Prototype your part with CNC—no tooling, fast iterations
2. Validate form, fit, and function under real conditions
3. Stamp it once the design is locked, maximizing ROI

Case Study: EV Battery Clamp

An automotive startup used CNC for early-stage testing of a battery clamp. After 3 rounds of functional tuning, we transitioned to stamping with a custom die set.
Result: 55% lower cost per part at volume, without compromising precision.

Avoid These Common Pitfalls

We often step in when things go sideways. Here’s what to avoid—and how:

Final Thoughts

Picking the right metal forming method isn’t just about machines—it’s about strategy.

If you’re not sure which process fits your part best, or you want a second opinion, feel free to reach out.
We’re happy to review your drawings and offer a free design-for-manufacturing (DFM) consultation.

Let’s make sure your next launch is your smoothest yet.