Factors Affecting Part Manufacturing Costs and Advantages of Deep Drawing Process

Key Factors Leading to Higher Part Manufacturing Costs

As a commonly accepted guideline, greater part complexity typically translates to higher labor requirements during production, thereby pushing up manufacturing expenses. Several key elements can contribute to an increase in the cost of producing parts, which are detailed as follows:

Quantity of Part Features

The number of functional or structural features a part possesses has a direct impact on production costs. Each additional feature—such as holes, slots, threads, or custom contours—requires extra processing steps, specialized tools, and quality checks. For instance, a simple flat component with no extra features can be produced in a single stamping operation, while a part with multiple threaded holes and recessed areas may need drilling, tapping, and milling processes sequentially, significantly adding to labor and time costs.

Position of Part Features

The spatial location of features on a part also plays a crucial role in determining manufacturing costs. Features that are located in hard-to-reach areas—such as internal cavities, narrow gaps, or irregularly curved surfaces—demand more precise machining equipment and skilled operators. For example, a hole drilled on the outer surface of a cylindrical part can be completed quickly with standard equipment, but a hole positioned inside a deep, narrow groove may require specialized angle drills or robotic machining systems, increasing both equipment investment and production time.

Orientation of Part Features

The direction in which part features are oriented relative to the primary processing direction often affects production efficiency and cost. If features are oriented in multiple different directions, the part may need to be repositioned or clamped multiple times during processing. This not only increases setup time but also raises the risk of positioning errors, requiring additional quality inspection steps. For instance, a part with features oriented horizontally, vertically, and at 45-degree angles will need multiple machining setups, whereas a part with all features aligned in the same direction can be processed in a single setup.

Projecting Part Features

Protruding features—such as bosses, ribs, or lugs—can increase manufacturing costs due to the challenges they pose in processing and tooling. These features may require specialized tooling to avoid collision during machining, or additional steps to ensure structural integrity. For example, a part with tall, thin protruding ribs is prone to deformation during machining, so slower cutting speeds, specialized fixturing, and additional cooling may be necessary to maintain precision, all of which add to production costs.

Part Dimensions and Material Thickness

The overall size of the part and the thickness of the material used both influence manufacturing costs. Larger parts require more raw material and larger processing equipment, which has higher operational and maintenance costs. Variations in material thickness can also increase complexity: uneven thickness may require additional material removal or forming steps, while extremely thin or thick materials demand specialized processing techniques to prevent defects. For example, producing a large metal housing with variable wall thickness requires precise rolling to adjust material thickness and large-scale stamping equipment, leading to higher overall costs compared to a small, uniformly thick component.

Advantages of the Deep Drawing Manufacturing Process

The deep drawing manufacturing process offers significant benefits to a wide range of manufacturing industries. This forming technique is particularly well-suited for producing small to medium-sized hollow components, such as solenoid valve casings and assembly enclosures—parts that are in high demand in the automotive and electromechanical industries. Its ability to create complex hollow shapes with consistent wall thicknesses makes it a preferred choice for these sectors, where precision and durability are critical.

Beyond automotive and electromechanical applications, the deep drawing process is also widely utilized in other key industries. In the medical field, it is used to produce components like syringe barrels and medical device housings, where hygiene and dimensional accuracy are paramount. It is also a staple in the production of household appliances (e.g., compressor housings, cookware), industrial equipment (e.g., pump components), HVAC systems (e.g., duct fittings), and building supplies (e.g., metal fixtures and fittings).