Our impressive design engineering department utilizes Solidworks for our 3D tooling designs. Our tools are built in-house in our very modern tooling department. A challenge of completing a die design in 3 weeks is not uncommon. From progressive stamping dies to specialized forming dies, our engineers are equipped to model, prototype, and engineer the tools for your job. 

We are experienced in the designing of progressive dies, blank dies, line dies, and transfer dies.

We offer the latest design and manufacturing solutions to make design and manufacturing development processes faster and more efficient. Our experience with a widely used CAD package makes Solidworks the obvious choice for moving our designs forward.

Die Design

3D modeling


From concept to completion, our 3D modeling and CAD team uses Solidworks software to develop a proven tool design that will perform in our customer’s manufacturing process. This means we are able to test and validate the complete design prior to tool manufacturing. It also ensures that prototype tooling and early parts are designed for cost efficiency and tested for part validity.

DYNAFORM allows Falcon to bypass soft tooling, reducing overall tryout time, lowering costs, increasing productivity & providing complete confidence in die system design.  It also allows for the evaluation of alternative and unconventional designs & materials. 

By simulating every detail during the design stage, DYNAFORM ensures the highest quality formed part & most efficient manufacturing process possible. 

Blank Size Engineering (BSE)
BSE is widely used for estimating blank size, along with blank nesting for maximum material usage, scrap & piece price. The plug-in is used to predict thinning, thickening & also  to generate a forming limit diagram (FLD).

Die Face Engineering (DFE)
A complete die face engineering package, this plug-in is used to create tooling design, including binder and addendum, from the part geometry. 

Formability Simulation (FS)
FS facilitates the rapid development & validation of  single-station & progressive die designs. It uncovers hidden problem areas & enables designers to optimize designs based on accurate forming results.

Die System Analysis (DSA)
DSA efficiently predicts many stamping related concerns within the die production line. It is used to analyze scrap shedding/removal, die structural integrity & sheet metal transferring/handling.

Optimization Platform (OP)
This new module helps users to go beyond identifying problem areas, by incorporating design optimization to improve performance and quality - reducing wrinkling, thinning and tearing.