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Connector terminals stamped from copper alloy at 0.1-0.5mm thickness require +/-0.01-0.02mm tolerances at 200-600 SPM.
## Press Requirements
- BDC repeatability: +/-0.005mm or better
- Slide parallelism: 0.005mm per 300mm
- Only direct-drive servo presses can reliably achieve these specs
## Die Requirements
- Die clearance: 3-5% of material thickness per side
- Die material: carbide punches and dies
- Guide pins: 0.002mm clearance
## Strip Feed
At 400 SPM, feed must advance in under 50ms with +/-0.01mm accuracy:
- Servo feed with closed-loop position control
- Synchronized to press encoder output
- Strip tension control to prevent wander
## Quality Control
- Vision system in die: check geometry every stroke
- Contact force tester: sample 1 in 1000 parts
- Automatic reject before reel-up