CAPABILITIES Metal Stamping Services Tool & Die Design & Manufacturing CNC Precision Milling 5 Axis Laser CuttingEquipment List EXAMPLES OF OUR WORKDeep Drawn Stamping of a Galvanized Steel Bus Roof Cap Design and Manufacturing of a Progressive Die for a Fluorescent Light Fixture Housing Design and Manufacturing of Transfer Tooling for the Automotive Industry CNC Machined Forged Billet 7050 Aluminum Aircraft Fittings for the Aerospace & Defense Industry Contract Metal Stamping for the Automotive Industry

Deep Drawn Metal Stamping of a Galvanized Steel Bus Roof Cap

As a metal stamping manufacturing source for the transportation industry, Dekalb Tool & Die, Inc. manufactures galvanized steel roof caps for buses, manufactured with eight different hole configuration variations. The main process used in manufacturing this cap is deep drawn metal stamping utilizing Dekalb Tool and Die's 1,800 ton large double action press, stamping a 12" deep draw into a 52" x 112" galvanized steel blank with a .047" (18 ga.) thickness.

After deep drawn metal stamping, DeKalb Tool & Die uses a precision Mitsubishi VZ-1 5-axis laser for the laser trimming and hole creation process. The use of the laser eliminates the need for an additional trim die thus creating lower tooling costs for the customer and a more efficient production run with the requirement for multiple variations. Working with one of Dekalb Tool and Die's finishing production partners, the galvanized steel roof cap metal stampings are then finished with a powder coat, and the finished metal stampings are shipped and delivered to Dekalb Tool & Die's customer located in the Southeastern U.S on a Dekalb Tool and Die truck.

Deep Drawn Stamping of a Galvanized Steel Bus Roof Cap

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Deep Drawn Metal Stamping Project Highlights

Metal Stamping Product Description   This sheet metal stamped bus roof cap was custom manufactured in 8 different variations in a low volume part run.
Metal Stamping Capabilities Applied/Processes  
Deep Drawn Metal Stamping Laser Trimming
Metal Stamping Equipment & Laser Used to Manufacture Part  
1,800 Ton Large Double Action Press
  • 800 Ton Max Binder Pressure
Mitsubishi VZ-1 5-Axis Laser
  • 2000 Watt
  • 122" x 87" x 33"
Overall Part Dimensions of Metal Stamping  
Blank Size:
Depth of Draw:
Number of Metal Stamping Variations   8
Metal Stamping and Laser Manufacturing Process Benefits  
5-Axis Laser Flexibility Allows for:
Multiple Trim Lines
Hole Variations
Lower Tooling Costs
Metal Stamping Tightest Tolerances  
Trim Line ± .03 Hole Position ± .015
Metal Stamping Material Used   18 Ga. Galvanized Steel
Metal Stamping Finish   E-coat base/ Powder Coat Finish (Out sourced)
Estimated Part Weight   21 lbs
Industry for Use   Truck, Bus and Heavy Equipment
Metal Stamping Volume   5,000
Delivery Location   Southeastern USA
Standards Met   Customer supplied print, 2D CAD Drawing
Product Name   Bus Roof Cap

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