Deep drawing makes it possible to produce components with a simple geometric shape such as wheel arch liners for vehicles.
A plastic sheet of ABS, polystyrene or polyethylene, for example, is heated by an infra red beam to its thermoelastic temperature range and drawn over a mould. In order to ensure the plastic sheet is drawn perfectly into the mould, boreholes are used to generate a negative pressure between the mould and the plastic sheet. Once it has cooled down, the plastic will have hardened and can be removed from the mould
We can produce the mould from a 3D CAD model by building a tool in the CAD software which takes the optimum necessary draft angles and possible undercuts into consideration. This can then be milled. A pattern making material such as the quickly milled Ureol is usually used. However, Ureol is unsuitable for larger batch quantities. In this case, there is the option of creating a plastic resin mould with which it is possible to conduct some several hundred deep-drawing cycles. However, in most cases, we will mill a die from aluminium, as this is more suitable for volumes larger than 1,000 pieces, or for series production.
Wall thicknesses range from 0.1 mm to approximately 50 mm according to the material.
Whether you require just one or several prototypes, deep drawing is a cost effective alternative, in particular for large components.