From prototype to high-volume production, we engineer progressive and transfer tooling in-house to deliver tight-tolerance parts with Class-A
cosmetic finishes and PPAP-ready documentation.
Precision metal stamping is a foundational capability FKI USA has built its business around. From our 100k+ sq. ft. Texas manufacturing center, we operate as a core, high-volume supplier for major OEMs and Tier 1 partners.
Our comprehensive stamping services are designed to meet the full spectrum of your manufacturing needs— from simple brackets and structural components to complex, “Class A” cosmetic enclosures. We have integrated our high-capacity stamping fleet with an 18k sq. ft. in-house tool and die shop and an advanced metrology lab, allowing us to provide a stable, reliable, and cost-effective supply chain for all your stamped components.
Precision metal stamping is the core of our 104,000-square-foot Texas manufacturing center. We have the right process for your project part’s geometry, volume, material, and cost target.
High-speed, high-volume automated stamping. See our close-tolerance Minster lines and 600-ton presses running heavy-gauge steel up to 0.250" thick.
Our technical advantage for the most complex parts. See how we use transfer stamping to form intricate geometries not possible in a progressive die.
Our "Class A" cosmetic specialty. See how we manufacture flawless, complex deep draw components like brushed stainless steel appliance panels.
As a core supplier, we have built our systems to provide three guarantees: Uptime, Quality, and Reliability.
Your production schedule is our top priority. Our 18,000 sq. ft. in-house
tool and die shop is your insurance against downtime.
When a die crashes, a competitor’s line can be down for weeks. Our in-house process—combining Tool Steel welding, and or Detail Fabrication, in-house heat-treating, and precision grinding—can turn a multi-week, line-down crisis into a 24-hour in-house fix.
100% Domestic Build for maximum speed & ITAR compliance or Hybrid Offshore Build to achieve lower costs depending on customer location and preference.
Tooling Takeover: Unhappy with your current supplier? We are experts at taking over and refurbishing your existing tooling to run in our presses.
We are not just a build-to-print shop; we are a manufacturing partner. Our US-based
engineering team de-risks your project before a single piece of steel is cut.
We work with your team to optimize your part for high-volume automated stamping, reducing cost and eliminating potential failure points.
We digitally simulate the entire stamping process. We predict material flow and warpage before we build the tool, saving you months of costly physical trial-and-error.
Our in-house Metal Fabrication Center (with its 12kW lasers and 440-ton press brakes) serves as our prototyping hub, allowing you to test functional parts before committing to hard tooling.
We prove our precision on every part. Our quality lab validates both our in-house tooling and your final production, led by a “Complementary Metrology Strategy”. This domestic lab is the core of our “Global-Local” Model.
Our Texas-based team provides local PPAP submission support and responsive ECN/ECR management.
A large-format Zeiss CMM provides automated inspection for First Article Inspections (FAI) and formal PPAP reports.
A 7-axis Hexagon Absolute Arm allows for rapid on-machine inspection and reverse engineering.
We have engineered our entire facility for 100% uptime. We don’t just fix problems; we prevent them.
Our Digital Nitrogen Cylinder Test Station validates die spring pressures before a run, preventing the most common cause of die crashes.
A single compressor failure can stop an entire plant. Our facility is powered by a 3x 50HP redundant air compressor system (Eaton and Kaeser), a deliberate investment in 100% plant-wide reliability.
We use a West Bend Coil Up Ender to safely and mechanically rotate 20,000-pound steel coils, protecting material, equipment, and delivery schedules.
Our automated progressive die lines are built for high-volume production, precision, and heavy-gauge capability. We operate a flexible cell of Minster E2-200 Hevi-Stamper presses, renowned for their ability to hold close tolerances at high speeds (up to 150 SPM).
For heavy-duty jobs, our fleet includes a 600-ton Blow press and twin 400-ton Verson lines. These automated systems are fully integrated with coil feed lines capable of handling:
Transfer stamping is a key capability that provides a cost-effective alternative to progressive dies for highly complex parts.
In this process, the part is separated from the coil strip by Laser Blanking and moved independently between stations. This allows for greater freedom in design, enabling us to perform complex forming, deep drawing, and trimming operations on large parts with intricate geometries. This process is often ideal for deep, non-symmetrical parts or those requiring features on all sides.
We are experienced in the process of deep draw stamping, a capability essential for manufacturing seamless part geometeries, three-dimensional parts. This is a core part of our ability to produce “Class A” cosmetic components for the appliance and automotive industries.
Our process mastery allows us to form challenging materials, such as brushed stainless steel, into flawless components like appliance doors, cooktops, and panels. Our large-bed Verson presses (up to 132 inches) provide the power and die space required for these large-format parts.
For maximum speed and control, our 18,000 sq. ft. Texas toolroom can engineer, build, and qualify your entire die set in-house. This is the ideal path for rapid development, complex ECNs, and ITAR-controlled projects.
Get the best of both worlds. We build your tool at our state-of-the-art global facility to achieve significant cost savings. Then, to eliminate all risk and uncertainty, the tool is shipped to our US facility for a comprehensive, on-site qualification, buy-off, and PPAP managed entirely by our local Texas engineering team.
Unhappy with your current supplier? We are experts at managing tooling transfers. Our engineering team can take your existing tooling, run a full validation in our advanced metrology lab, and use our in-house toolroom to refurbish, repair, and get it running in one of our presses, minimizing production gaps.
We carry the certifications that allow you to sell into regulated markets. Our quality lab features Zeiss CMMs for certification and Hexagon Portable Arms for reverse engineering.
EV & ICE
Turnkey Cosmetic Assemblies
Complete Box Builds
Simplify your supply chain with a partner who can handle the entire bill of materials. We integrate
our core stamping capabilities with in-house tool & die services, heavy metal
fabrication, and complete electro-mechanical assembly.
Explore our fabrication capabilities, featuring advanced laser processing and high‑tonnage stamping to support complex assemblies for demanding applications.
Take a deep dive into our “Closed-Loop Die Repair” process. We have 100% in house die repair and build capabilities ensuring your production requirement
From a single component to a fully tested and integrated electro-mechanical assembly.
We simplify your supply chain. See how we integrate stamped parts, plastics, PCBs,
and harnesses into a complete, kitted, and tested “box build.”
From 12kW laser blanking to 440-ton heavy plate forming.
With two advanced fiber lasers and a comprehensive lineup of brake presses, we deliver high‑precision metal fabrication from cut to formed.
FKI USA is strategically positioned to serve the high-growth, high-precision electronics and Electric Vehicle (EV) markets. Our facility is home to specialized “gold standard” assets designed specifically for this work.
Our Minster and Komatsu presses offer high-speed, high-precision machines designed for one purpose: the extremely high-volume production of small, intricate parts.
This press is the ideal machine for manufacturing:
EV Motor Laminations (Stators and Rotors)
High-Speed Electrical Connectors
Precision Terminals and Lead Frames
These specialized high speed presses, combined with our in-house toolroom (featuring Charmilles Wire EDM) and our advanced Zeiss CMM inspection lab, creates a complete, vertically integrated solution.
This makes FKI USA the perfect domestic partner for your most demanding, high-volume, and high-precision electronics projects.
We are not just a stamping shop; we are a complete manufacturing partner. Our 104,000 sq. ft. Texas facility provides a stable, single-source solution. We integrate high-capacity stamping, an 18,000 sq. ft. in-house toolroom, and an advanced metrology lab to control your project from concept to delivery.
Our Texas-based engineering and program management
team is your single point of contact. We provide
responsive, local ECN/ECR support and manage all your PPAP submissions, saving you the time and risk of global supply chain management.
Our quality systems are built for the world's most demanding industries. We hold key certifications including ISO 9001:2015 and ITAR compliance.
We manufacture critical components for leading OEMs in the Appliance, Automotive, and Aerospace industries. See the complex, high-volume parts we've built in our gallery.
Find quick answers to common questions about our stamping processes,
tooling, certifications, and how to get started on your project.
Yes. We operate a fully-equipped, 18,000 sq. ft. in-house tool and die shop. We design, build, and provide lifetime maintenance for all our progressive dies, transfer tooling, and fixtures.
Our in-house toolroom provides a “Closed-Loop Die Repair” workflow. We can pull a crashed die, re-harden it in our in-house heat-treat ovens, and precision-grind it. This can turn a potential multi-week, line-down crisis into a 24-hour in-house fix.
Yes. We are experts at managing tooling transfers. Our toolroom and metrology lab are fully equipped to receive your existing die, validate it (using our 7-axis Hexagon CMM arm), and refurbish, repair, and maintain it for production in our presses.
Yes. FKI USA is ITAR compliant. We have strict protocols for handling all technical data related to the United States Munitions List (USML) and can legally manufacture defense-related components in our Texas facility.
This is our specialty, particularly for the appliance and automotive industries. We are experts at deep drawing materials like brushed stainless steel to produce flawless, defect-free surfaces for high-visibility parts like doors, panels, and trim.
Yes. Our US-based engineers are partners in your design. We provide full DFM services and digitally simulate the entire stamping process. This predicts material flow and warpage before we cut steel, saving you months of costly trial-and-error.
Our domestic quality team can provide all levels of PPAP documentation, from Level 1 to a full Level 5. We manage the entire submission, including dimensional layouts from our Zeiss CMM, process flow diagrams, and initial process studies.
Our domestic facility operates 11 presses ranging from 110 to 600 tons. Our automated coil lines can handle material up to 0.250 inches thick and 20,000-pound coils. We also offer access to our global fleet of over 620 presses, including machines up to 2,000 tons.
Our NPI process is managed by your dedicated US-based Project Engineer. It’s designed to de-risk your launch and includes:
DFM & Simulation: We start with DFM to optimize your design before building the tool.
Prototyping: We use our in-house laser cutters and press brakes to create functional prototypes for validation.
Tooling Path: We help you select the best tooling model (e.g., our “Hybrid Model” for cost savings).
Qualification: We provide a full PPAP (Level 1-5) submission from our Texas-based quality lab.
We are a full “box build” manufacturer. We go beyond just the stamped chassis or enclosure. Our electro-mechanical assembly services are IPC-A-610 compliant and include full integration of PCBs, cables, harnesses, power supplies, and final testing, all managed by our US-based team.
Our capability is defined by more than just tonnage. Our heavy-duty press lines (up to 600 tons) feature massive bed sizes up to 132 inches (11 feet) long. This allows us to run large, complex progressive dies for heavy-gauge structural parts, industrial components, and large appliance panels.
Yes. Our 4,000 sq. ft. metal fabrication center is a standalone capability. In addition to our 12kW laser and 440-ton press brake, we operate a Cole Tuve Plate Roller. This specialized machine allows us to form 3D shapes like cylinders, cones, and tank shells, making us an ideal partner for the rail, energy, and heavy industrial markets.
Our US-based project and tooling engineers are ready to review your design, discuss DFM, or plan your tooling transfer. Get the right technical answers, fast.
