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Deep Drawing & Metal Fabrication

We have 110 years of experience deep drawing metal. Our integrated facility in New Jersey combines multi-draw capabilities with a full range of secondary operations, light assembly and finishing services. We have the expertise to solve your most complicated metal drawing needs — and we deliver shorter lead times, higher quality & lower costs!

American Aluminum Company is a leading manufacturer of deep drawn parts, including cylinders, enclosures and irregular shapes. We maintain a vertically-integrated facility with on-site engineering, designing, and prototyping services. Over the last 110 years, we’ve earned a reputation for producing highly complex, yet cost-effective, deep drawn parts.

    We start with blanks up to 48" in diameter and make deep drawn parts ranging from ½"-24" wide with depths up to 24"
    Aluminum, brass, bronze, copper, Hastelloy®, Inconel®, Monel®, mu-metal, nickel, stainless steel, steel, titanium, & specialty metals
    Anodizing, assembling, blanking, CNC machining, dip brazing, forming, iriditing, heat treating, Heliarc® welding, painting (wet & powder), piercing, spinning, spot welding, trimming & swedging.

Deep Drawing and Secondary Operations

Deep Drawing can be a multi-draw operation performed on a specially prepared metal blank. The process lends itself to multiple draws using separate draw tools for each draw operation; resulting in a seamless (void-free) part. Our proprietary approach results in a higher quality part and usually eliminates the need to perform X-Ray analysis to confirm void-free fabrication integrity. Once a part has been Deep Drawn it can be followed by secondary operations which range from custom fabricating to light assembly to finishing.

Amalco is uniquely equipped to perform a full range of secondary operations including: CNC machining, spinning, welding (Heliarc & Spot) dip-brazing, heat treating (Aluminum), anodizing, iridite & painting (Powder & Wet); all performed on-site. Only one purchase order is needed to complete most processes under one roof and under the control of our comprehensive quality assurance program in our clean and efficient facility.

Deep Drawing Process

The first step in deep drawing a metal part is choosing the right material

If you haven’t specified a material our expert engineers will help you determine which alloy will best conform to your specifications. We normally source the material for you or we can work with customer-supplied material. We first cut the material into the proper size blanks.

The next step is preparing the blanks for the draw process

Our engineers take great care to prepare each metal blank according to its properties, which maintains the integrity of the alloy and prevents cracks and tears in the finished product.

Once the blank is prepared, the deep drawn part is formed by drawing the metal blank around a punch as it's pulled through a die. The edges of the metal blank are restrained by a blank holder or sleeve.

A key benefit of deep drawing, compared to hydroforming, is the ability to perform multiple re-draws.

Each draw can produce a 43% reduction of the metal blank. Greater depths, up to 24″ can be achieved through multiple draws, which reduce the diameter and increase the height of the previously drawn shell.

Since deep drawn metal parts are made from a solid piece of sheet metal the resultant part is seamless (no welded seams or corners). Therefore, there is no need, in most cases, for additional pressure testing or x-rays to find voids or cracks in the metal.

If you are wondering if Amalco can deep draw your part, take a look at our Deep Drawn Parts Gallery to get a sense of our capabilities.

Deep Draw / Deep Drawing Considerations

Common shapes for Deep Drawn / Deep Draw parts are cans, boxes, and bottles, as well as irregularly shaped products.

Deep Drawing / Deep Draw can achieve a 43% reduction. Numerous re-draws can be performed on deep drawn parts to attain the desired depth.

Check with our Engineering Support as early as possible in your product development, even before designs are finalized. We’ve been making metal parts in the USA for over 110 years, and have earned a reputation for deep drawing and hydroforming parts other shops declined to quote.

Benefits of Deep Drawing with Amalco

When you choose Amalco as your manufacturer of deep drawn parts, you get:

Design & Engineering Expertise

We’ve been manufacturing complex, seamless metal shapes — including cylinders, boxes, enclosures, and irregular formations — for 110 years. Our experts know exactly how to prepare and handle each alloy, and our zero defects policy ensures complete customer satisfaction.

Reliable Customer Service

Our expert engineers are available to help you with each step of the process, from finalizing your CAD drawings, to choosing and souring the alloy, to selecting the secondary operations you need.

Value-Added Services

We perform many secondary operations on-site, from assembling deep drawn parts to blanking, welding, and finishing. Doing it all in-house generally results in cost savings, fewer defects, higher quality finished pieces and less paperwork (single purchase orders).

Contact Amalco’s engineering support team as early as possible in your product development process. We can help you save money on tooling and production costs, while also delivering shorter lead times than the competition. Send us your CAD drawings today, and our expert engineers will help you get started.


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Economics of Deep Drawing

The tooling for Deep Drawing / Deep Draw requires a punch, die and blank holder. Therefore, if cost is a factor in the design/manufacture of your part we invite you to contact Amalco’s engineering support team to confirm Deep Drawing is the best solution prior to completing your design. We may be able to offer you an alternative process which can lower costs.

Quality System (Conforms to MIL-I-45208)

With our MIL-Grade Quality System External link, our commercial customers enjoy the same critical quality control standards that have allowed us to deliver Defense Department contracted products for many years. Amalco employs the latest technologies in its QC inspection processes, and maintains its own QC Manual focused on a goal of “Zero Defects on All Products Produced.”

Design and Engineering Support for Hydroforming and Deep Drawn Metal

With 110 years and four generations of experience, Amalco offers design and engineering support for customers in need of deep drawn and hydroformed metal parts. Our team is ready to help you solve design challenges and answer your hydroforming process and deep drawing process questions. If you are new to metal forming and fabrication, Professor Metal is here help you get started.

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