Investigating the Formability of SS304 and AA6061 in Cup Drawing Operation via Additively Manufactured Tools.

The industrial manufacturing landscape is rapidly evolving, with increasing adoption of advanced methods for designing, producing, and prototyping critical components. Additive manufacturing (AM) has become a key enabler in this transition, offering cost-effective solutions for complex designs and material challenges. In sheet metal manufacturing, AM is gaining traction for fabricating essential tools such as dies, punches, and blank holders, allowing manufacturers to address complex geometric and process parameters in product formation. This study focuses on the design, fabrication, and validation of the drawing process and its tools via fused deposition modeling (FDM) with the PLA Pro material. A 3D-printed punch and die set was developed considering key parameters such as the drawing ratio and punch-die clearance. Experimental trials were conducted on a hydraulic press using AA6061 and SS304 metallic sheets of 1 mm thickness to evaluate the performance of the printed tools in drawing operation. The drawn samples were analyzed for geometric conformity, whereas the tools were assessed for durability, deformation behavior, failure limits, and cost comparison. The statistical results show the potential of using polymer-based tooling for low-volume production and prototyping in sheet metal forming. A drawing ratio of approximately 56% was achieved with a consistent geometry in both materials, validating the feasibility of AM-fabricated tools in small-volume production. The cost comparison between PLA Pro and steel tools reveals a 9% price reduction when using polymer-based tools.