Deep-Drawn Exhaust Aftertreatment Caps for Heavy-Duty Vehicles
Six-week tooling turnaround and 18 % material saving on stainless-steel components.
Quick Facts
- Customer: Global heavy-duty emission-systems OEM
- Sector: On- & off-road exhaust aftertreatment
- Component: End Caps, Seal Units, & Closure Cap
- Volume: 1,200,000
- Lead‑time: 6 weeks Tool Development, 1 Week First Off Approval
Customer Profile
The Challenge
Engineering Solution
Design-for-manufacture sessions converted CAD into draw-friendly geometries and optimised blank nesting.
Six-week tool build: multi-stage deep-draw dies with replaceable wear inserts for high-temperature 1.0 mm stainless 304.
Press-line allocation: Bruderer 60 T high-speed progression for seal units, Chin Fong 400 T progression for large end caps, S&B 50 T single-op press for closure-cap prototyping and low-volume spares.
One-week on-site commission, culminating in first-off parts that met dimensional requirements.
Innovation & Value‑Add
Results & KPIs
| Metric | Before | After | Benefit |
|---|---|---|---|
| Material usage (kg / 1 M parts) | Baseline | –18 % | £ saving tracks stainless index |
| Tool build time | — | 6 weeks | Met launch window |
| Commission to first parts | — | 1 week | Zero delay |
Customer Quote
“The thinner-gauge redesign cut our material bill by nearly a fifth without compromising strength.”
Visual Proof
Certifications & Related Case Studies
Tech Specs
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Material: Stainless Steel 304
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Gauge: 0.8, down to 0.08 mm
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Presses: Bruderer 60 T (progression), Chin Fong 400 T (progression), S&B 50 T (single-op)
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Post-processing: Degreasing, helium leak-test
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Tolerances: ±0.05 mm on flange concentricity
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