# Frontier Metal Stamping, Inc.

This MFR.ID profile was supplied, reviewed, and approved by Frontier Metal Stamping, Inc.. Originally approved on 9/9/2025; last updated 2/12/2026. Capability data is manufacturer-approved for public sourcing and RFQ use.

## Profile Links

- Canonical profile: https://mfr.io/frontiermetal
- JSON data: https://mfr.io/frontiermetal.json

## Company Overview

Frontier Metal Stamping, Inc. is a family-owned precision metal stamper in Frederick, Colorado. From a single 25,000 sq ft, ISO 9001:2015 certified plant, the team designs and builds tooling in house and runs progressive die stampings on presses up to 260 tons with coil feed. Stamping is backed by CNC machining, wire EDM, press brake, robotic and manual welding, deburring, assembly, and inspection, so customers can move from prototype to high-volume production with one supplier. Frontier serves aerospace and defense, automotive and transportation, electronics, medical equipment, construction products, agriculture/turf care, and energy/mining. They provide PPAP/FAI and inspection reporting when required, and support JIT programs (kanban/VMI, scheduled releases, tailored packaging and barcoding). The focus is straightforward: meet spec, deliver on time, and scale with demand. The lot adjacent to the plant is reserved for future expansion.

## Quick Reference

- Processes: Metal Stamping, Wire EDM, Tool & Die (Fixtures & Gages), Prototype Tooling Design & Build, Inspection & Quality Control, Secondary Operations & Value-Added Services
- Lead Time: 2-6 weeks
- Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts)
- Location: Frederick, CO 80516
- Employees: 10-49
- Revenue: $5M-$10M
- Founded: 1984
- Contact: jonathan@frontiermetal.com - +1 888-316-1266
- Verified: Manufacturer Approved

## Capabilities

### Precision Metal Stamping & Forming

Frontier delivers high-volume, precision metal stampings using mechanical and servo presses with progressive and single-station tooling. Coil-fed production, electronic feed control, and in-die operations enable efficient blanking, piercing, bending, embossing, and coining. Press capacity and bed size are matched to geometry and alloy, supporting prototypes through mass production with repeatable tolerances, robust die maintenance, and integrated quality controls.

- Process: Metal Stamping
- Highlights: Progressive and single-station stamping for repeatable, scalable production, Coil-fed automation with servo roll feeding and straightening, In-die operations: tapping, clinching, selective hardware insertion, Press range supports thin- to mid-gauge alloys with tight features, In-house die maintenance and production monitoring for long tool life, ISO 9001:2015 quality with FAI, SPC/Cpk, and PPAP on request
- Subprocesses: Progressive Stamping, Punching, High-Tonnage Blanking, Deep Drawn Stamping
- Specifications:
  - Feature Tolerance (General): -0.005-0.005 in (-0.127-0.127 mm) - Typical across most stamped features with well-designed tooling and in-process control.
  - Stroke Rate: 10-150 spm (10-150 spm) - Typical operating window across the press lineup; higher rates may be achievable on small parts in high-speed cells. Confirm per tool.
  - Coil Width (Servo Fed): 0.5-24 in (12.7-609.6 mm) - Automated decoilers, straighteners, and servo roll feeders support continuous coil-fed production.
  - Practical Die/Part Envelope In Press: Min: 12L x 12W in (304.8L x 304.8W mm), Max: 48L x 24W in (1219.2L x 609.6W mm) - Approximate part/die size window that runs efficiently across the press fleet; confirm per part during DFM.
  - First Article Lead Time After Tool Completion: 1-2 weeks - Covers initial production run, inspection, and documentation package.
  - Finishes Available Via Managed Partners: Anodizing (sulfuric, hard-coat), Chromate conversion coating, Electroless/electrolytic nickel, Gold plating, Chrome plating, Black oxide, Passivation, electropolishing, Industrial paint and powder coat, Heat treating - Finished parts supplied turnkey with certifications per print/spec.
  - Quality Controls And Documentation: ISO 9001:2015, First Article Inspection (FAI), In-process inspection and press/tonnage monitoring, SPC with Cp/Cpk reporting, Material and finish certifications, PPAP available on request - Lot traceability and documentation packages supplied per customer requirements.
  - Press Bed Size (Max): 48L x 32W in (1219.2L x 812.8W mm) - Maximum bed footprint used for tooling; usable window varies by press model, shut height, and feedline.
  - Repeat Order Lead Time: 1-3 weeks - Typical for standard finishes; plating/anodize may add time based on queue.
  - Expedite Lead Time (Stocked Items): 0-1 weeks - Same-day shipment available for stocked parts via inventory programs; otherwise expedited scheduling on request.
  - Tool Steels And Coatings: Tool steels: D2, A2, S7, M2, M4, A11 (CPM 10V); carbide inserts where justified, Surface treatments/coatings: TiN, TiCN, AlCrN, nitriding - Selection based on alloy thickness/strength, feature density, and expected tool life; finalized during tool design.
  - In Die Operations: Tapping, Clinching, Selective hardware insertion, In-die sensing/vision (presence, misfeed, tonnage monitoring) - Integrating operations in-die reduces handling and improves positional accuracy for critical features; electronic monitoring improves process reliability.
  - Max Material Thickness (Coil Fed): 0.01-0.25 in (0.254-6.35 mm) - Typical working range; upper limit depends on alloy, feature density, and tool design.
  - Representative Presses And Feedlines: Straight-side presses up to 260 ton, Servo press 220 ton, Gap-frame presses 50–260 ton, OBI presses 45 & 60 ton, Automated decoilers, straighteners, and servo roll feeders (up to 24 in width) - Tooling and press selection are matched to geometry, alloy, and target strokes-per-minute.
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Programs scale from prototypes to sustained mass production; stocking and JIT releases available for steady demand.
  - New Tooling Lead Time: 3-14 weeks - Includes tool design, build, and tryout; varies with complexity and station count.
  - Core Stamping Operations: Blanking, Piercing/punching, Bending, Lancing, Flanging, Hemming, Embossing, Coining - Operations can be sequenced within progressive tooling to minimize secondary processing and increase throughput.
  - Common Materials: Cold-rolled steel (CRS), HRPO, HSLA, Stainless steel (301, 304, 316), Aluminum (5052, 6061), Copper alloys (brass, phosphor bronze, beryllium copper) - RoHS-compliant options supported; additional alloys available upon request.
  - Prototype Lead Time: 1-2 weeks - 3–10 days typical depending on method; expressed in weeks for consistency.
  - Burr Allowance (Post Blank/Pierce): 0.0005-0.003 in (0.0127-0.0762 mm) - Typical as-stamped burr height; controlled via die clearance and punch condition. ≤10% of material thickness typical. Lower burr achievable with fine clearances and post-process deburring.
  - Feature Tolerance (Critical Achievable): -0.003-0.003 in (-0.076-0.076 mm) - Tighter limits possible on select features (down to ±0.001 in / ±0.025 mm) using optimized tooling or secondary sizing.
  - Press Capacity: 5-260 ton (44.5-2313 kN) - Covers small precision features through heavy blanking/forming; press is selected to match part tonnage and die size.

### Wire EDM

Frontier’s wire EDM cuts any conductive material with non-contact spark erosion, enabling sharp internal corners, fine features, and stable accuracy after heat treat. Submerged cutting, automatic wire threading, and process monitoring support unattended runs for die components, insert details, and production parts with tight tolerances and refined surface finish.

- Process: Wire EDM
- Highlights: Submerged wire EDM of hardened steels, carbides, and superalloys, Tight dimensional control with minimal burr and no cutting forces, Fine finish capability with multi-pass skim strategies, Automatic wire threading and re-thread on break for unattended cutting, Process stable after heat treat—no distortion from cutting loads
- Subprocesses: Wire EDM Straight & Taper Cutting, Wire EDM Fine Skim & Mirror Finish, Wire EDM Stack / Multi-Up Cutting, EDM Drilling (Fast-/Micro-Hole), CNC Programming & Post-Processing Services, Polishing / Grinding, Lapping
- Specifications:
  - Kerf Width (Typical By Wire Size): 0.010 in wire → ~0.011–0.013 in kerf - Kerf depends on wire size, power settings, and dielectric condition; used for offset programming and clearance planning.
  - Taper Cut Capability At 4 In Height: -15-15 deg (-15-15 deg) - Programmable UV axes support compound tapers; angle limit scales with part thickness.
  - Wire Diameter Range: 0.01-0.01 in (0.254-0.254 mm) - Fine wires enable tight inside radii and micro-features; larger wires increase removal rate on thick sections.
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Unattended cutting and palletized setups enable efficient small-to-medium batches; large volumes evaluated case-by-case.
  - Lead Time – Prototype EDM Blanks: 1-2 weeks - Simple profiles and insert details; dependent on material availability and finish requirements.
  - Wire EDM Travel (X × Y × Z): 16L x 24W x 16H in (406.4L x 609.6W x 406.4H mm) - Representative X/Y/Z cutting envelope for die plates and insert details; verify part fixturing and flush access at quote.
  - Minimum Inside Corner Radius (With 0.010 In Wire): 0.006 in (0.152 mm) - Approximate achievable inside radius equals half kerf; smaller radii achievable with finer wire at reduced removal rate.
  - Lead Time – Fine Detail Die Components: 2-4 weeks - Includes rough/skim passes, heat-treat coordination (if required), and inspection.
  - Maximum Workpiece Height (Submerged Cut): 16 in (406.4 mm) - Tall work supported with submerged cutting to stabilize flushing and heat removal.
  - Dielectric Fluid Type: Deionized water for wire EDM - Water-based dielectric enables fine finish and efficient flushing; resistivity maintained via DI system.
  - Dimensional Tolerance Capability (Fine Finish): -0.0001-0.0001 in (-0.0025-0.0025 mm) - Achieved via multi-pass skim strategies and controlled offsets on critical details.
  - Start Hole Diameter (Pre Drill/EDM Drill): 0.02-0.12 in (0.508-3.048 mm) - Hole size set by wire diameter and flushing requirements; micro-holes possible with dedicated EDM-drill.
  - Dimensional Tolerance Capability (Typical): -0.0002-0.0002 in (-0.005-0.005 mm) - Typical positional/size control on well-fixtured parts after thermal soak.
  - Surface Roughness Achievable (Ra): 8-125 µin (0.2-3.2 µm) - Roughing to finishing passes tailored to print; finest finishes used on shut-offs and sealing features.
  - Removal Rate: Metric: 20-300 mm²/min - Representative material removal area rate from skim-quality to aggressive roughing on medium-thickness steels.
  - Applicable Workpiece Materials: Tool steels (D2, A2, H13, S7, M2, PM grades), Stainless steels (300/400 series, precipitation-hardening), Tungsten carbide and carbide-tipped details, Titanium and nickel-based superalloys (Inconel/Hastelloy), Copper, brass, and aluminum alloys - Any electrically conductive material can be cut; post-EDM surface may require polish or lap depending on application.
  - Tool Steels And Coatings (Mating Die Details): Tool steels: D2, A2, S7, H13, M2, M3, M4, A11; carbide inserts where justified, Surface treatments: TiN, TiCN, AlCrN, nitriding; polish/lap shut-offs - Selected to balance wear life and toughness for the stamped alloy and run rate.
  - Inspection And Documentation: CMM verification of critical profiles and datums, FAI/PPAP dimensional reports on request, Material and heat-treat certifications - Dimensional packages align with downstream tool assembly or part print requirements.
  - Automation And Work Changer Options: Automatic wire threading (AWT) with re-thread on break, Submerged cutting with programmable flush, Tooling/palletization for repeatable setups, Program queue for unattended operation, In-process break detection and recovery - Supports lights-out cutting of long contours and multi-part nests.
  - Lead Time – Repeat Production EDM: 1-2 weeks - Standard reorder of qualified parts or details with established programs and fixtures.

### Tooling Design & Build

Frontier operates a full in-house tool and die department that designs, builds, validates, and maintains progressive and transfer dies as well as production fixtures and gages. The toolroom integrates CNC machining, wire and sinker EDM, precision grinding, and controlled heat treat to produce durable, quick-change tooling. In-house capability accelerates DFM feedback, tryout correlation, and die-wear programs, supporting multi-million-shot production at stable cost and lead time.

- Process: Tool & Die (Fixtures & Gages)
- Highlights: End-to-end die design, build, tryout, and maintenance, Wire/sinker EDM for fine features in hardened tool steels and carbide, CNC machining and modular fixture design for quick-change tooling, Bench proofing with documented preventive maintenance to maximize uptime, PPAP-ready dimensional reporting via CMM; ISO 9001:2015 quality system
- Subprocesses: Die Manufacturing (Tool & Die), Electrical Discharge Machining (EDM), CNC Machining, Wire EDM, Production Tooling & Fixture Design
- Specifications:
  - Wire EDM Travel (X × Y × Z): Min: 8L x 12W x 8H in (203.2L x 304.8W x 203.2H mm), Max: 16L x 24W x 16H in (406.4L x 609.6W x 406.4H mm) - X/Y/Z mapped to width/length/height respectively for schema consistency.
  - Die/Mold Base Size Limit (Max): 58L x 36W in (1473L x 914W mm) - Maximum base footprint routinely supported for progressive/transfer dies; confirm bolster pattern and shut height at quote.
  - Simulated Press Stroke Capacity: 260 ton (2591 kN) - Press-capacity simulation used for tool design/validation and tryout correlation (≈1,600 kN, about 180 US tons).
  - Software And File Formats: SolidWorks, AutoCAD, STEP (AP203/AP214), IGES, Parasolid (x_t/x_b), DXF/DWG, CAM for EDM/CNC (Mastercam/Esprit or equivalent) - Native and neutral CAD supported; CAM outputs verified during NC and burn program reviews.
  - Post Hardness Range (Typical): 52-62 HRC - Representative hardness range for working inserts in D2/H13/S7; finalized per material and duty cycle.
  - Wire EDM Max Workpiece Thickness: 0.02-12 in (0.5-304.8 mm) - Range depends on machine, flushing strategy, and wire selection.
  - Grinding Feature Tolerance (Typical): -0.0002-0.0002 in (-0.005-0.005 mm) - Flatness, parallelism, and size control on finished tool steel components.
  - Lead Time – New Progressive Die (Design + Build): 4-12 weeks - Includes DFM, design, machining/EDM, assembly, tryout, and documentation; varies with station count and complexity.
  - Maximum Tool Weight: Up to 4000 lb (Up to 1814 kg) - Representative crane/rigging capacity for die handling. Heavier tools may be accommodated with special arrangements—confirm per program.
  - Material Options For Inserts: P20, H13, S7, D2, A2, M2, M3, A11, PM-M4, Tungsten carbide (select features) - Tool-steel selection balances wear resistance, toughness, and cost for the target alloy and run rate.
  - Cycle Life Guarantee (Shots): 100000-5000000 shots - Life-of-tool programs with scheduled sharpening and insert replacement; life depends on alloy, thickness, and coating.
  - Lead Time – New Transfer Die (Design + Build): 6-16 weeks - Accounts for larger base, lifters/cams, and transfer tooling complexity.
  - CNC Machining Travel (X × Y × Z): Min: 16L x 20W x 16H in (406.4L x 508W x 406.4H mm), Max: 60L x 30W x 20H in (1524L x 762W x 508H mm) - 3- to 5-axis vertical machining capacity for plates, inserts, and die shoes.
  - Turnaround – Emergency Repair: 0-1 weeks - Same-day/overnight support available depending on scope and material availability.
  - Achievable Tool Build Tolerance (EDM/Ground Features): -0.0002-0.0002 in (-0.005-0.005 mm) - Typical on precision punch/die details and shut-offs using wire EDM, jig grinding, and controlled lapping.
  - Fixture Datum Repeatability: -0.0005-0.0005 in (-0.0127-0.0127 mm) - Modular 3-2-1 welding/machining fixtures with repeatable datums for fast changeovers.
  - Lead Time – Engineering Change / Tool Modification: 1-4 weeks - Simple insert swaps faster; major re-cut/heat-treat on the longer end.
  - Surface Grinding Table Size (Max): 24L x 12W in (609.6L x 304.8W mm) - Magnetic chuck and precision fixtures used for parallelism and flatness on die components.
  - Quality Controls And Documentation: ISO 9001:2015, First Article/bench tryout reports, CMM inspection with full dimensional layouts, PPAP Level 3 documentation available - Traceable tool build records and inspection packages supplied on request.
  - CMM Envelope (X × Y × Z): Min: 24L x 20W x 16H in (609.6L x 508W x 406.4H mm), Max: 40L x 28W x 24H in (1016L x 711.2W x 609.6H mm) - Representative inspection volume across in-house Zeiss/Mitutoyo CMMs; full PPAP Level-3 dimensional reports available.
  - Hardening And Surface Treatments: Vacuum heat treat, Cryogenic stabilization, Gas/ion nitriding, PVD coatings: TiN, TiCN, AlCrN, Black oxide (fixtures/components), Polish/lap to mirror shut-offs - Treatments and coatings specified for wear life, galling resistance, and consistent break-edge.
  - Sinker EDM Travel (X × Y × Z): Min: 8L x 12W x 10H in (203.2L x 304.8W x 254H mm), Max: 16L x 24W x 16H in (406.4L x 609.6W x 406.4H mm) - Graphite/copper electrodes supported; burn strategies tuned for finish vs. MRR.
  - Wire EDM Wire Diameter: 0.01-0.01 in (0.254-0.254 mm) - Fine wires for tight radii and micro-features; larger wires for faster roughing and long-taper cuts.

### Engineering Reviews & Prototyping

Frontier provides engineering reviews and prototype services to accelerate development and validate manufacturability before production release. Services include DFM reviews, rapid prototype tooling, and short-run blanks using laser, waterjet, EDM, and CNC. 3D-printed fixtures and tooling-board masters support fit/form/function checks while minimizing upfront investment and shortening time to first article.

- Process: Prototype Tooling Design & Build
- Highlights: DFM and manufacturability reviews to optimize cost, yield, and process flow, Rapid prototype tooling and short-run blanking for first-article validation, Hybrid prototype methods: laser/waterjet blanks, wire EDM, CNC, 3D-printed fixtures, Closed-loop feedback from tryout to design for faster iteration
- Subprocesses: Rapid 3D-Printed Tooling, Laser / Waterjet Blanking (Springs)
- Specifications:
  - Prototype Methods: Laser-cut sheet blanks, Wire EDM blanks and fine features, CNC-machined prototypes, Soft/prototype dies and hand-forming, 3D-printed check gages/fixtures, Press brake forming for simple bends - Method is selected to balance speed, fidelity to production, and cost per iteration.
  - Formed Prototype Bend Angle Tolerance: -1-1 deg (-1-1 deg) - Applies to simple press-brake or hand-form bends; tighter control requires hard tooling or secondary sizing.
  - Bend Radius Guidelines: CRS: inside radius ≈ 1.0× material thickness, Stainless: inside radius ≈ 1.0–1.5× thickness, Aluminum: inside radius ≈ 0.8–1.0× thickness - Guidelines for early design; final radii are validated via coupon trials and springback compensation.
  - Lead Time – Soft Tooling / Hand Form Prototype: 2-4 weeks - Includes fixture/gage prints, setup, and first-article evaluation.
  - Lead Time – DFM Review: 0-1 weeks - Simple prints can be turned in days; complex assemblies may require additional time for stack-ups and process routing.
  - Supported File Formats: SolidWorks, STEP (AP203/AP214), IGES, Parasolid (x_t/x_b), DXF/DWG, PDF for drawings - Native and neutral CAD accepted; drawings with defined GD&T expedite DFM and inspection.
  - Waterjet Cutting Tolerance (Typical): -0.02-0.02 in (-0.508-0.508 mm) - Useful for thicker blanks or heat-affected-zone avoidance; edge taper minimized via quality setting and speed.
  - Formed Flange Length Tolerance (Typical): -0.015-0.015 in (-0.381-0.381 mm) - Dependent on bend radius, material, and method; improved with gauged stop features.
  - DFM Scope And Deliverables: Tolerance and stack-up analysis with datum scheme recommendations, Formability review: bend radii, grain direction, reliefs, springback planning, Process selection and cost drivers (progressive vs. stage vs. secondary ops), Material recommendation and thickness review, Risk assessment and control plan inputs (FMEA-light, CTQ identification), Gauge/inspection plan and sampling strategy, Actionable design edits and updated CAD when authorized - Structured review artifacts are issued as a brief report or red-lined CAD/drawing package to speed decisions.
  - Inspection And Documentation: FAI reports with ballooned drawings, CMM or comparator spot-checks on critical features, Material/finish certifications as applicable, PPAP documentation available on request - Inspection scope scales with risk and program phase; critical features verified before design freeze.
  - Common Prototype Materials: Cold-rolled steel (CRS), HRPO, HSLA, Stainless steel (301, 304, 316), Aluminum (5052-H32, 6061-T6), Copper alloys (brass, phosphor bronze, beryllium copper), Tooling board, ABS/PLA (for fixtures and masters) - Material selection mirrors production intent; plastics and boards used for fixtures and master patterns.
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Pilot lots can bridge from prototypes to production while process capability is validated.
  - Prototype Material Thickness (Flat Blanks): 0.01-0.25 in (0.254-6.35 mm) - Typical working range for laser/waterjet/EDM prototypes aligned to production stamping gauges.
  - Laser Cutting Tolerance (Typical): -0.01-0.01 in (-0.254-0.254 mm) - Typical profile tolerance band; features ≥0.060 in allow tighter control (down to ±0.005 in) depending on geometry.
  - CNC Machined Prototype Tolerance (Typical): -0.003-0.003 in (-0.076-0.076 mm) - Critical features on machined prototypes can reach ±0.001 in with appropriate fixturing and toolpaths.
  - Trial Finishes (As Requested): Deburr/vibratory tumble, Passivation (stainless), Anodize or chromate conversion (aluminum), Black oxide (carbon steels), Powder coat or wet paint (appearance/protection) - Prototype finishes simulate production surfaces for functional and cosmetic evaluation.
  - Lead Time – Prototype Blanks (Laser/EDM): 1-2 weeks - Depends on material availability, feature density, and finishing requirements.
  - Prototype Blank Envelope (Laser/Waterjet): Min: 1L x 1W in (25.4L x 25.4W mm), Max: 96L x 48W in (2438.4L x 1219.2W mm) - Larger blanks may be split into nested segments and re-located with tooling pins.

### Inspection & Quality Control

Frontier’s ISO 9001:2015–registered quality system uses calibrated metrology, documented plans, and closed-loop SPC to control incoming, in-process, and final inspection. Capabilities include CMM 3D measurement, vision-based metrology, optical comparators, and gage-based checks. Deliverables include FAI/PPAP data packs, Cp/Cpk studies, traceable calibration records, and customer-tailored inspection reports for aerospace, automotive, and industrial programs.

- Process: Inspection & Quality Control
- Highlights: ISO 9001:2015 quality management with documented control plans, CMM/vision/comparator dimensional inspection integrated with SPC, Gage calibration and Gage R&R programs with traceable certificates, Customer-ready data packs (FAI, PPAP) with Cp/Cpk and full layouts
- Subprocesses: 3D Coordinate Measurement, Dimensional Inspection, Gauge Calibration & Gage R&R Management, First Article Inspection (AS9102)
- Specifications:
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Inspection scales from prototype FAIs to full production PPAP and ongoing SPC monitoring.
  - Environmental Control—Temperature: 66-70 °F (19-21 °C) - Parts are temperature-stabilized prior to high-accuracy CMM measurement.
  - Sampling Plans And AQL: ANSI/ASQ Z1.4, C=0 (zero acceptance) plans when specified, 100% inspection for safety/critical features - Plans selected by risk and defect history; tightened/normal/reduced switching rules applied as needed; sampling/AQL applied as required.
  - Data Outputs And Formats: PDF inspection reports, CSV/Excel data tables, Native CMM exports (e.g., PC-DMIS, MCOSMOS), QIF or DMIS exchange when supported, Image markups from vision/comparator - File naming and lot traceability match customer PO and drawing revisions.
  - CMM Table—Max Part Weight: 0-40 lb (0-18 kg) - Heavier parts may be supported with special fixturing or alternative measurement methods.
  - Lead Time – Capability Study (E.G., 30 Piece): 1-2 weeks - Includes study plan, data collection, and Cp/Cpk report. Pricing negotiable for capability studies.
  - Lead Time – FAI Dimensional Package: 1-2 weeks - Includes ballooned drawing, full measurements, and certificates.
  - Bore Gage Diameter Range: 0.125-6 in (3.175-152.4 mm) - Two-point and three-point systems used; masters traceable to NIST.
  - Optical Comparator Stage Travel (X × Y): Min: 6L x 6W in (152.4L x 152.4W mm), Max: 12L x 18W in (304.8L x 457.2W mm) - Suitable for profiles, thread forms, and edge locations; overlays and DXF comparison available.
  - Optical Comparator Magnification: 30-300 × - Typical lens set; select magnification to balance field of view and feature resolution.
  - CMM Measurement Uncertainty (Typical): 0.00003-0.00009 in (0.0008-0.0023 mm) - Applies to well-fixtured parts after thermal soak; complex geometries may require feature-specific uncertainty statements.
  - Thread Gage Coverage: UNC/UNF/UNEF, Metric coarse/fine, NPT/NPTF - Go/No-Go plug and ring gages with current calibration certificates.
  - Gage R&R Target (%GRR Of Tolerance): 0-10 % - Aim ≤10% for critical characteristics; investigate at 10–30% per MSA guidance. Pricing for related studies is negotiable.
  - Lead Time – Routine Lot Inspection Report: 0-1 weeks - Typical for standard lots; expedite available when coordinated at PO.
  - Inspection Methods: Incoming inspection, In-process inspection, Final inspection, First Article Inspection (FAI), PPAP dimensional and capability studies - Scope is defined by control plan and risk; critical-to-quality features receive heightened sampling.
  - Vision Field Of View (Per Frame): Min: 0.4L x 0.5W in (10.16L x 12.7W mm), Max: 1.5L x 2W in (38.1L x 50.8W mm) - Small FOV supports fine features at high resolution; larger FOV speeds general dimensional checks.
  - Surface Roughness Measurement (Ra): 0.01-125 µin (0.000254-3.175 µm) - Contact stylus profilometer used for functional and cosmetic surface validation.
  - Pin Gage Coverage: 0.011-0.75 in (0.279-19.05 mm) - Class ZZ/plus–minus sets maintained; certificates available upon request.
  - Hand Metrology Ranges: Calipers: 0–12 in (0–300 mm), Micrometers: 0–6 in (0–150 mm), outside/inside, Height gages: 0–24 in (0–600 mm) - Used for rapid checks and lot verification; calibrated to internal schedule.
  - SPC Metrics And Charts: X̄–R and X̄–S charts, Individuals–Moving Range (I–MR), Cp/Cpk and Pp/Ppk indices, Run charts and histograms - Live data collection on critical features; capability indices included in reports when requested; SPC depth applied as required.
  - Quality System And Frameworks: ISO 9001:2015 registered, AS9102 FAI forms supported, AIAG PPAP (Level 1–3) supported, MSA (Gage R&R) and SPC per AIAG - Certificates and documentation packages provided per program requirements.
  - CMM Envelope (X × Y × Z): Min: 16L x 16W x 16H in (406.4L x 406.4W x 406.4H mm), Max: 40L x 28W x 24H in (1016L x 711.2W x 609.6H mm) - Represents inspection volume across in-house CMMs; larger parts can be sectionally verified or fixtured.
  - Lead Time – PPAP Level 3 (Dimensional + Capability): 1-3 weeks - Timing depends on sample size, capability studies, and supplier docs (material/finish certs).
  - Vision System Resolution (Edge Detection): 0.00003-0.00009 in (0.0008-0.0023 mm) - Resolution depends on lens, lighting, and field of view; verified by gage blocks and glass scales.
  - Environmental Control—Relative Humidity: 35-55 %RH - Humidity maintained to protect gages and ensure stable measurement conditions.

### Secondary Operations & Value-Added Services

Frontier consolidates in-house secondary operations to deliver finish-ready, assembly-ready components. Capabilities span deburring, cleaning, hardware insertion, threading, welding (robotic and manual), coating, and turnkey finishing via qualified partners. Integrating these steps with primary stamping reduces handoffs, improves quality continuity, and shortens lead time to shipment-ready assemblies or kitted subassemblies.

- Process: Secondary Operations & Value-Added Services
- Highlights: In-house deburring, cleaning, hardware installation, and threading, Manual and robotic welding for subassemblies and assemblies, Powder coating and managed plating/anodize with certificates, Kitting, labeling, custom packaging, and inventory programs
- Subprocesses: Deburring, Powder Coating
- Specifications:
  - Powder Coat Colors And Gloss: RAL or Federal Standard references, Custom colors to supplied chip, Gloss, semi-gloss, matte - Color and gloss matched to target; batch certification available.
  - Hardware Types: Self-clinching nuts, studs, standoffs, Swage and rivet fasteners, Threaded inserts (press-in, heat-set for plastics in fixtures) - Torque-out and push-out verification available on request.
  - Lead Time – Powder Coat: 1-2 weeks - Includes pretreatment, coating, cure, and inspection; color match may add time.
  - Black Oxide Conversion Layer: 0.00002-0.00004 in (0.5-1 µm) - Applied to ferrous parts for appearance and light corrosion resistance; usually oil sealed.
  - Powder Coat Cure Temperature: 350-400 °F (176-204 °C) - Typical metal temperature window; actual schedule per coating manufacturer TDS.
  - Chrome Plating Thickness (Decorative Or Functional): 0.0002-0.001 in (5-25 µm) - Decorative thickness shown; heavy build functional chrome available on request.
  - Powder Coat Cure Dwell Time: 0.17-0.33 weeks - Approximately 10–20 minutes at temperature; expressed in weeks for schema consistency.
  - Passivation Standards (Stainless): ASTM A967 (nitric or citric), AMS 2700 - Method selected by alloy and downstream finish requirements.
  - TIG Welding Material Thickness: 0.02-0.25 in (0.5-6.35 mm) - Used where heat input control and cosmetic beads are critical.
  - Electroless Nickel Thickness: 0.0002-0.001 in (5-25 µm) - Uniform deposition for complex geometries; phosphorus content per spec.
  - Assembly Services: Subassembly build and mechanical fastening, Adhesive bonding (per spec), Functional checks (fit, torque, thread verification) - Work instructions and QC checkpoints documented per control plan.
  - Lead Time – Kitting And Packaging: 0-1 weeks - Standard cartons and labels stocked; custom packaging on request.
  - Lead Time – Plating/Anodize: 1-3 weeks - Timing varies by finish type, cert requirements, and lot size.
  - Edge Break Target After Deburr: 0.003-0.01 in (0.0762-0.254 mm) - Typical controlled edge radius to remove burrs without altering fit surfaces.
  - Powder Coat Film Thickness: 1.5-4 mil (38-102 µm) - Measured via comb or DFT gauge; thickness depends on coating system and environment class.
  - Anodize Thickness—Type III Hardcoat: 0.001-0.004 in (25-100 µm) - Wear-resistant coating for aluminum; color typically dark due to thickness.
  - Lead Time – Hardware Insertion And Tapping: 0-1 weeks - Often completed within the stamping cell or as a short secondary step.
  - Welding Processes: GMAW (MIG), manual and robotic, GTAW (TIG), manual, Resistance spot welding - Process selection depends on alloy, thickness, joint design, and production rate.
  - Anodize Thickness—Type II: 0.0002-0.001 in (5-25 µm) - Decorative/corrosion protection; clear or dyed with sealed pores.
  - Tapping Methods: Cut tapping, Roll forming (thread forming), In-die tapping (select parts) - Method selected by material, thickness, and thread engagement requirements.
  - Resistance Spot Welding Stack Thickness (Steel): 0.01-0.125 in (0.25-3.18 mm) - Range assumes typical carbon steels; aluminum spot welding on request with dedicated electrodes.
  - MIG Welding Material Thickness: 0.04-0.375 in (1-9.5 mm) - Typical sheet and plate range for fillet and butt joints; thicker sections on request with joint prep.
  - Cleanliness And FOD Controls: Visual and wipe tests, Gravimetric residue checks (per request), Particulate limits per VDA 19.1/ISO 16232 (when specified) - Cleanliness criteria are documented in the control plan for critical applications.
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Secondary operations scale with demand; bundled with stamping for flow and shorter lead time.
  - Kitting, Packaging, And Labeling: Custom kitting with part segregation, ESD-safe packaging when specified, Barcoding/labeling to PO and revision, Protective wraps, trays, and dunnage - Packaging designed to protect surface finish and simplify line-side use.
  - Chromate Conversion (Aluminum) Classes: Class 1A (maximum corrosion protection), Class 3 (electrical conductivity/contact) - Applied per MIL-DTL-5541 or equivalent; RoHS options available.
  - Cleaning Methods: Aqueous wash with surfactant, Ultrasonic cleaning (small parts/fixtures), Solvent wipe or vapor degrease (as specified) - Method aligned to downstream welding or coating requirements.
  - Threading Range (Tapping/Forming): #4-40 through 1/2-13 (UNC/UNF), M3 through M12 (metric coarse/fine) - Cut tapping and roll forming supported; holes prepared per class-of-fit.
  - Deburring Methods: Vibratory tumbling, Barrel tumbling, Mechanical/brush deburring, Hand deburring and edge break - Media and cycle time tuned to part geometry to protect critical surfaces.
  - Surface Pretreatments: Iron phosphate (steel), Zinc phosphate (corrosion class upgrade), Chromate conversion (aluminum), Media blast for adhesion profile - Pretreatment selected for environment rating and adhesion durability.
  - Resistance Weld Nugget Diameter (Typical): 0.08-0.25 in (2-6.4 mm) - Actual nugget size validated by peel tests and destructive checks per print.
  - Weldable Materials: Cold-rolled steel (CRS), HRPO, HSLA, Stainless steel (301, 304, 316), Aluminum (5052, 6061) - Filler selection and precleaning per alloy; weld procedures tailored to joint geometry.
  - Inventory And Delivery Programs: Kanban and Min/Max, Vendor-managed inventory, JIT releases, Drop shipments - Schedules synchronized to customer demand; stocking levels agreed in advance.
  - Gold Plating Thickness: 3-50 µin (0.08-1.27 µm) - Contact and corrosion applications; underplate (Ni) as specified.
  - Lead Time – Welding And Subassembly: 1-2 weeks - Depends on fixture complexity, inspection scope, and volume.
  - Hardware Insertion Press Capacity: 2-16 ton (17.8-142 kN) - Supports self-clinching nuts, studs, standoffs, and similar hardware; sizing per manufacturer tables.
  - Powder Coat Adhesion Tests: ASTM D3359 cross-hatch (4B–5B typical), MEK double rubs (per TDS), ASTM D3363 pencil hardness (per spec) - Adhesion verified per customer-specified method; substrate prep and cure are key drivers.
  - Corrosion Resistance (Salt Spray Target): 96-1000 h - Representative ASTM B117 performance window depending on finish system and pretreatment. Exact hours per print/coating TDS.

## Certifications

- ISO 9001:2015 (Type: Certification; Authority: International Organization for Standardization (ISO); Status: Active; Scope: Stamping of metal and associated materials with precision tooling, machining of stamped products, welding of aluminums and steels, assembly and finishing of stamped and machined products; URL: https://www.iso.org/iso-9001-quality-management.html)

## Industries Served

- Aerospace & Defense: Precision stampings, tooling, and assemblies for aerospace and defense programs under ISO 9001:2015 quality management with inspection reporting, material traceability, and documentation (e.g., FAI/PPAP) as required by customer specifications.
- Automotive & Transportation: High-volume progressive stampings and assemblies for automotive and transportation customers with ISO 9001:2015 controls, PPAP/FAI support, scheduled releases, and JIT/kanban supply.
- Electronics & Semiconductors: Stamped and fabricated metal components for electronics and commercial/industrial devices (e.g., brackets, terminals, shields, enclosures) with precision tooling and secondary machining/welding as needed.
- Medical Devices & Healthcare Equipment: Precision metal parts and sub-assemblies for medical equipment/devices manufactured under ISO 9001:2015 with required inspection records and documentation to customer requirements.
- Agriculture & AgriTech: Durable stamped components and welded assemblies for agriculture and turf-care equipment with emphasis on strength, wear resistance, and consistent supply via scheduled releases/JIT.
- Energy & Power Generation (inc. Renewables): Precision metal stampings and assemblies for energy and mining customers with ISO 9001:2015 quality controls and supply programs aligned to site schedules.
- Construction Products & Building Materials: Stamped components, brackets, and light assemblies for construction products and building materials, supplied to schedule with barcoding/packaging to project needs.
- Consumer Goods & Appliances: Metal components and assemblies for consumer goods and appliances with integrated tooling, secondary ops, and tailored packaging/labeling to support high-volume production.

## Facilities

### Frontier Metal Stamping Headquarters

Single-site 25,000-sq-ft headquarters and plant with full tool & die, coil-fed progressive stamping (presses to ~260-ton class), turret punch and press brake for fab/short-run work, CNC machining and wire EDM for tooling and secondary ops, robotic/manual welding, deburring, assembly, inspection, and shipping. Central Front Range location (north of Denver/I-25 corridor) supports regional logistics; adjacent lot owned allows rapid footprint expansion.

- Type: manufacturing_facility
- Headquarters: Yes
- Email: info@frontiermetal.com
- Phone: +1 888-316-1266
- Address: 3764 Puritan Way, Frederick, CO 80516, USA

## Verification Status

- Business Entity: Verified 8/11/2025
- Technical Capabilities: Verified 9/9/2025
- Locations & Facilities: Verified 8/11/2025
- Reviews & Ratings: Not yet verified
- MFR.ID Created: 7/30/2025
- Last Updated: 2/12/2026