Deep drawing is an often underestimated, seldom understood, metal forming technology. Yet deep drawing offers solid advantages in the overall design process. In "deep drawing," metal is "formed" into the desired end shape by a series of "dies" or tooling. Once the tooling is selected and set up in the appropriate press, producing upwards of two- to three-hundred parts per hour is not uncommon.
Since multiple tools are required to generate the finished product, deep drawing is usually not the most cost-effective method to produce prototype parts or parts that have annual quantities of less than approximately 400 to 500 pieces, especially if new tooling is required. The set up time for a deep drawing process is much more than that for a machining operation. Setting up the punches and dies in the press takes hours of costly manual labor. However, the larger the production quantity, the less impact the cost of tooling has on the individual part cost.
The versatility of the tooling used in deep drawing allows for many exotic materials to be formed, including kovar, nickel, beryllium copper and tantalum as well as the more common steel, aluminum and stainless steel. These materials, because of their lower level of availability, are very expensive to purchase and, oftentimes, very difficult to obtain in large quantities. The wasteful nature of many machining processes, such as milling and turning, makes machining parts from these materials a very uneconomical approach. This concern is not an issue for deep drawing, which forms parts to the desired shape with a minimal amount of wasted material. The only waste that might result would be from a few minor machining operations at the end of the process to trim off some excess material. At Gasser & Sons, we are committed to giving our customers the highest quality in precision components, at a competitive price. In order to attain this, we utilize a variety of processes such as deep drawing, stamping and machining to provide the most cost-effective fabrication alternatives available.