Could this flat steel clip be formed without a stamping die?

Could this flat steel clip be formed without a stamping die?

A trading company approached us with a drawing for a new car window sunshade clip. The part is made from flat steel wire, 11 mm wide and 1.4 mm thick. There are three slightly different versions, supplied as one set.

Our first thought was stamping. But before committing to a die, we asked our engineers and machine setup team whether the part could be formed on a CNC spring machine.

The estimated stamping die cost was around RMB 13,000 (approximately US$1,900). The custom machine attachments needed for the CNC forming approach cost around RMB 400 (approximately US$60). After reviewing the shape and running trials, we confirmed that CNC forming was feasible.

The development work took three sampling rounds. The large bend radius required custom attachments and careful machine adjustments. Based on the customer’s feedback, we refined the curvature until the formed samples were approved, about one month after the first samples.

The customer also specified a black sprayed finish, a 72-hour salt spray requirement, and UV resistance. Working with our surface treatment supplier, we completed the sample finishing within two days and submitted the finished parts for approval.

The project is now in production, and we have delivered 10,000 sets.

For flat-wire parts that may need shape changes during development, it can be worth assessing CNC forming before investing in stamping tooling. The right process still depends on the part geometry, requirements, and production volume.

Have a flat-wire part in development? Send us the drawing, and we can assess whether CNC forming is a practical option.