What Is Deep Drawn Manufacturing?

Deep-drawn stamping is a manufacturing method of forming sheet metal called blanks into parts of complex shapes and features.

Typically, single blanks are used to manufacture parts and components with thick bases and drawn sides. At each step in the deep drawing process, the metal blank is shaped through the extreme pressure applied by a metal die.

Deep drawing is used to create components from a wide range of materials, including aluminium, copper, brass, steel, and stainless steel. Standard shapes from deep-drawn products include housings and enclosures for the likes of solenoid valves and assemblies.

The deep drawing process results in highly accurate parts that conform exactly to the drawing regardless of the sheet thickness or complexity of the tool, including undercuts.

Key Benefits Of Deep Drawn Manufacturing

Speed and Efficiency

Deep-drawn stamping is usually the most efficient method of high-volume manufacturing when large quantities of parts are required regularly.

Punch presses are designed to operate at high speeds and can be equipped with automatic material feeds for enhanced efficiency.

Eliminates Assembly Steps

Deep-drawn components are also created in one piece, thereby reducing the need for additional assemblies such as cutting or welding.

A deep drawn component has the added benefit of seamless construction. That makes deep drawing an ideal process for water, air or gas-tight applications.

High Accuracy Manufacturing Process

Deep-drawn stamping is highly versatile and can be used to create complex, precision components with a great degree of accuracy and repeatability. Once the tooling is made correctly, the deep-drawn parts will conform exactly to the part drawing and provide a highly repeatable process for part manufacture. The final parts are a reliable solution that allows customers to consume parts in assembly line manufacturing with reduced throughput and product quality risks.

Deep Drawing Produces Very Strong Parts

The deep drawing method work hardens the metal, due to the extreme amount of compression exerted on the metal during the forming process. This results in finished components that are measurably stronger than machined or otherwise cast metal components.

When to use Deep Drawing?

Deep-drawn component manufacturing

The deep drawing method of manufacturing produces high-accuracy parts of considerable strength and minimum weight. Producing cylindrical-shaped parts from deep drawing is the most common practice with this manufacturing method, as the metal blank can easily be shaped in a minimum number of steps.

Of course, more complex geometries such as squares, and rectangles may be slightly more complicated to manufacture but can still be effectively and efficiently produced with the deep drawing process.

Manufacturing experts will look at several factors to determine if deep drawing is the most viable production solution. These factors are addressed in the design stage to determine whether deep drawing is the most suitable and cost-effective process to produce the parts and may include one or more of the following:

Does the Part Require a Seamless Construction?

The majority of deep-drawn parts are produced from a single blank for seamless construction. This removes the need for costly secondary operations and ensures the parts are kept in good quality.

Are High Volume and Quick Production Runs Needed?

The requirement for large quantities of parts, manufactured easily through deep drawing.  

Are Complex Cylindrical Parts Required?

The shape and dimensions of the specific part determine whether it is suitable for deep drawing. Deep drawing is a highly accurate manufacturing process for cylindrically shaped parts like enclosures and housings.

Types of Deep Drawn Components

Stainless Steel Deep Drawn Housings & Enclosures

Deep-drawn housings and enclosures are used in several industries, such as automotive, electronics and industrial. These parts can be complex with tight tolerances manufactured in a multi-stage progression tool from mild, stainless steel. The parts have a thick base and drawn sides. Other parts are made from individual die sets with others from ultra-high pressure cold forming tool sets.

Solenoid and Valve Housing

Hydraulic solenoid valves are widely used in aerospace, construction, automotive and many other industries that require hydraulic systems. These parts must be highly accurate and finished to customer requirements such as zinc plating.

What are the factors that might increase part cost?

As a general rule of thumb, the more complex the part, the more labour-intensive it is to produce, and the higher the cost of manufacturing.

The following factors may result in an increased manufacturing cost.

• The number of part features.

• Location of part features.

• The direction of part features.

• Protruding part features.

• Part size and Material thickness.

benefit from the Deep Drawing Manufacturing Process

Nearly all manufacturing industries could benefit from the deep drawing manufacturing process. This manufacturing method is most useful for producing small parts such as solenoid valve housings, and assembly housings required by manufacturers in the automotive and electromechanical fields.

Other applications include medical, appliances, industrial, HVAC and building supplies.

About Donlouco Ireland Ltd

Donlouco has extensive experience manufacturing deep-drawn components, supplying clients operating in the automotive and Industrial applications space, for the manufacturing of Solenoid Valves.

Donlouco can produce parts from single die sets to complex progress multistage tool die sets for higher volume.

Tools include drawing and forming operations to increase flexibility for intricate part design while maintaining a low price point on individual parts. These tool sets can be used to make standard precision parts to high tolerance parts & fine blanking parts with complex shapes and multiple part features.

Capabilities to Produce a Wide Range of Deep Drawn Parts

Donlouco can review the design solution and offer more efficient and appropriate manufacturing options that best suit the customer and the market sector.

One of the common drivers in developing new parts is to reduce cost, simplify the product, reduce part numbers and improve performance. Donlouco has developed and honed the skills, knowledge, and understanding over the years and can help customers greatly in achieving their design goals both from an engineering and commercial point of view.