Rapid tooling with polymer tools: dry deep drawing process of aluminum and stainless-steel blanks

This study investigates the performance of polymer tools in a dry deep drawing process applied to stainless steel and aluminum blanks. The tools were manufactured via material extrusion additive manufacturing using a polyamide matrix reinforced with short carbon fibers. Circular blanks with a diameter of 70 mm and thickness of 1 mm were formed into cups with a drawing depth of 15 mm. The experiments aimed to evaluate dimensional accuracy and tool wear after up to 50 forming cycles. A direct comparison between aluminum and stainless steel forming showed that aluminum cups maintain high accuracy and tool integrity over time, while stainless steel induces more tool deformation and geometric deviations. FEM simulations supported the experimental findings by reproducing the observed trends in cup geometry and tool displacement. The successful dry deep drawing of aluminum parts demonstrates the potential for lubricant-free processing, making the method more sustainable, faster, and cost-effective. These findings highlight the role of rapid tooling in promoting sustainability within small-batch deep drawing processes.