In modern industrial production, there is a tendency to optimize manufacturing processes, with a special emphasis on reducing waste and energy consumption as well as maximizing manufacturing flexibility. In forming processes, customers' need to narrow manufacturing tolerances increases production complexity, forcing all manufacturing companies to seek new, innovative forming solutions. As an example of an innovative, flexible stamping process concept, the "Smart mechatronic progressive tool for stamping standard products" project established the adaptation of mechatronic tool operation to a pre-programmed product shape to optimize the operation of mechatronic progressive stamping tools. With a single forming tool, its flexibility allows us to manufacture several different geometrically similar products while minimizing waste when changing the component produced by the selected tool. The article presents the concept of developing a single-cutting punch operation with mechatronic adjustment, for which a new, innovative direct-drive electromagnetic actuator was developed to raise and lower the active part of the forming tool. At the same time, we monitored the tool's and the built-in actuator's performance using their digital twins and established appropriate feedback loops for their control and operation. The presented concept of a stamping tool will be upgraded to a mechatronic stamping tool with a greater number of controlled punches, enabling the production of up to eight different products with the same progressive tool.
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