Making use of a wide range of tool and die capabilities, Dekalb Tool & Die, Inc. designed and manufactured a progressive die for use in the metal stamping production of a fluorescent light fixture housing.

Working from a supplied 2D CAD drawing, Dekalb Tool & Die engineers used MasterCam design and programming in preparation to manufacture the tooling in two segments that would be joined in the press. Dekalb Tool and Die’s CNC machining capabilities allowed for simultaneous 2D and 3-axis contouring of the tooling, which also underwent wire EDM machining, heat treatment, and surface grinding to meet the exact shape and dimensions required by the customer. The final dimensions of the die were 52″ x 144″, with all features machined to within ±.005″, and the final, 7 lb. two-segment piece was shipped to the customer for use in an 800 ton press with a 96″ x 144″ bed size.

Dekalb Tool & Die’s in-house die-mounting and die tryout service combined with CMM inspection guaranteed that the die tooling would be exactly what the customer required, and Dekalb Tool and Die’s unique two-segment solution saved the customer tooling time and costs by creating a more versatile piece.

Progressive Die Project Specifications

Progressive Die Product Description

This Light Fixture Housing Die Tooling was manufactured in two segments and joined in the press, and will manufacture the product from pre-painted coil stock.

Too & Die Capabilities Applied/Processes

Autocad-2D/ VISI -3D/ MasterCam Design & Program CNC Machining

  • 2-D & 3 Axis Simultaneous Contouring

WIRE EDM Machining

Heat Treatment
Surface Grinding
Die Mounting (Overhead crane capacity 30 Tons)
Die Tryout (In House)
CMM Part Inspection

Progressive Die Equipment Fitted to

800 Ton Press

  • 96″x144″ Bed Size
  • 18″ Stroke
  • 48″ Max. Shut Height

Feed Equipment

  • 60″ Max. Coil Width x .200″ Thick
  • 10″ Max Coil Width x .375″ Thick
  • 30,000lbs Max. Coil Weight
Overall Part Dimensions

Die Size:

Product Material Size: .026″x24.41″x48.310″

Progressive Die Characteristics

Built In Two Segments
Joined in the Press to Accommodate Specific Equipment

Progressive Die Tightest Tolerances

+/- .005″

Material Used

M4 High Speed Steel Cutting edges/ D2 Forms

Estimated Part Weight

7 lbs

Industry for Use


Progressive Die Part Volume

1 Per Stroke

Progressive Die Delivery Location

Southeastern USA

Criteria Met

Customer supplied print, 2D CAD Drawing

Product Name

Decorative Chrome Plated Stainless 20″ Wheel Cladding