Delta sash is an important part of automobile door, which has the functions of supporting and guiding seesaw of car’s window, preventing dust and air from outside. In previous manufacturing process, each part of the delta sash was independently formed by tandem processes, and rubber is bonded to steel by poisonous glue. So, the previous processes, including roll forming process and toxic gases, had low production rate and high failure rate. In this study, progressive process design of the delta sash was proposed in order to increase productivity and high utilization of the materials. And instead of the poisonous glue used for adhesion of rubber in the previous tandem process, embossing and piercing processes were designed in the new guide to help the rubber to adhere well to steel. And the optimal piercing distance was designed to ensure structural safety, and prototypes were manufactured for verifying reliability of the processes.
