Futuristic dry deep drawing process with robotic arm and volatile media lubrication.

Revolutionizing Manufacturing: How Dry Deep Drawing is Changing the Game

Mira Elwood in Tech & Innovation August 2025 • 3 min read.

"Discover how volatile media is transforming deep drawing, making it cleaner, more efficient, and sustainable. Learn about the groundbreaking research and practical applications that are setting a new standard in metal forming."

In today's manufacturing world, sustainability and the elimination of harmful substances are more than just buzzwords—they're critical drivers of innovation. Traditional deep drawing, a cornerstone of metal forming, often relies on mineral lubricants to reduce friction and prevent surface damage. However, these lubricants come with their own set of problems, including the presence of harmful additives like chlorinated paraffins.

These substances not only pose environmental and health risks but also require additional steps in the manufacturing process. Lubricants must be applied before forming and then meticulously removed to avoid interfering with subsequent processes like bonding, welding, and painting. It's a costly and time-consuming cycle that manufacturers are eager to escape.

Enter the groundbreaking technique of dry deep drawing, which replaces traditional lubricants with volatile media such as nitrogen or carbon dioxide. This innovative approach promises to eliminate harmful substances, streamline production, and significantly enhance the sustainability of manufacturing processes.

The Science Behind Dry Deep Drawing

Futuristic dry deep drawing process with robotic arm and volatile media lubrication.

The core principle of dry deep drawing involves introducing volatile media directly into the tools during the forming process. This creates a lubricating layer between the tool and the sheet metal, reducing friction and preventing wear. The real magic happens after the forming is complete: the volatile media evaporates without leaving any residue, eliminating the need for post-processing cleaning.

Researchers have been rigorously investigating the potential of dry deep drawing, focusing on understanding the friction conditions that occur during the process. These investigations often involve:

Flat Strip Drawing Tests: These tests help determine the achievable coefficients of friction using different volatile media and varying parameters like media pressure and the geometry of laser-drilled microholes.
Strip Drawing Tests with Deflection: This method examines friction conditions at tool radii, simulating the bending and pressure experienced in real-world deep drawing scenarios.
Deep-Drawing Tests of Rectangular Cups: These tests assess the feasibility and stability of the process, comparing it to conventional lubrication methods.

The results of these experiments are compelling. Studies show that using nitrogen (N2) or carbon dioxide (CO2) as lubrication significantly reduces the friction coefficient at low contact pressures. Moreover, CO2 has demonstrated superior performance in deeper drawing applications, likely due to its ability to form dry ice, which further enhances lubrication.

The Future of Manufacturing is Here

The transition to dry deep drawing isn't just about adopting a new technique—it's about embracing a new philosophy of manufacturing. By eliminating harmful substances, streamlining processes, and enhancing sustainability, dry deep drawing offers a pathway to a cleaner, more efficient, and more responsible future. As research continues and these methods are refined, we can expect to see even wider adoption of this transformative technology across various industries.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.1007/978-3-030-03451-1_72, Alternate LINK

Title: Investigation Of The Friction Conditions Occurring During Dry Deep Drawing Using Volatile Media As Lubrication Substitution

Journal: Advances in Production Research

Publisher: Springer International Publishing

Authors: Gerd Reichardt, Christoph Wörz, Mathias Liewald

Published: 2018-11-20

Everything You Need To Know

What is dry deep drawing, and how does it differ from traditional deep drawing methods?

Dry deep drawing is an innovative metal forming technique that substitutes traditional mineral lubricants with volatile media like nitrogen or carbon dioxide. This eliminates the need for harmful additives such as chlorinated paraffins, reducing environmental and health risks. The process involves introducing the volatile media directly into the tools during forming, creating a lubricating layer that evaporates after completion, leaving no residue and eliminating post-processing cleaning.

How do volatile media function as lubricants in the dry deep drawing process, and what happens to them after the forming is complete?

In dry deep drawing, volatile media, such as nitrogen or carbon dioxide, act as a lubricant between the tool and the sheet metal during the forming process. After forming, these media evaporate completely, leaving no residue. This eliminates the need for post-processing cleaning, which is a significant advantage over traditional deep drawing methods that use mineral lubricants.

What research tests are conducted to understand the friction conditions in dry deep drawing, and what specific aspects of the process do these tests evaluate?

Researchers use tests like flat strip drawing tests, strip drawing tests with deflection, and deep-drawing tests of rectangular cups to investigate friction conditions during dry deep drawing. Flat strip drawing tests determine achievable coefficients of friction. Strip drawing tests with deflection examine friction at tool radii, and deep-drawing tests assess the feasibility and stability of the process compared to conventional lubrication methods.

Why does carbon dioxide (CO2) show better performance in deeper drawing applications compared to nitrogen (N2) in dry deep drawing?

Carbon dioxide (CO2) has shown superior performance in deeper drawing applications within the dry deep drawing process because of its ability to form dry ice. This dry ice formation further enhances lubrication between the tool and the metal sheet, allowing for deeper and more effective drawing compared to using only nitrogen (N2). The unique properties of CO2 contribute to a more efficient and stable forming process in these specific applications.

What are the broader implications of adopting dry deep drawing in manufacturing, and how does it contribute to sustainability and efficiency?

By transitioning to dry deep drawing using volatile media like nitrogen or carbon dioxide, manufacturers can eliminate harmful substances such as chlorinated paraffins, streamline production by removing the need for post-processing cleaning, and enhance sustainability. This shift represents a new philosophy of manufacturing that prioritizes environmental responsibility and efficiency. The wider adoption of dry deep drawing can lead to a cleaner, more efficient, and more sustainable future for the manufacturing industry, reducing environmental impact and improving workplace safety.