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Custom Metal Fabrication & Manufacturing
AMALCO offers superior contract metal fabrication capabilities, including deep drawing and hydroforming metal forming processes. Our manufacturing equipment includes components designed exclusively by and for Amalco. As a vertically-integrated company, we're able to minimize costs and reduce lead times — while complying with our customers' detailed specifications and rigorous requirements. We possess the equipment needed to produce and assemble your most difficult, complex metal parts under one roof.
Our facility meets rigid Mil specs and standards required for Government, Aerospace, and Military products. As a result, our commercial customers also benefit from our adherence to these stringent standards.
Our team of expert engineers work closely with our sales, operations, QC, and production personnel in all facets of part development and manufacture. This approach allows us to produce the highest-quality products at competitive prices, while consistently exceeding customer delivery expectations.
Seamless Metal Fabrication Methods
Hydroforming and deep drawing processes produce seamless metal parts and eliminate much of the complexity associated with stamping, welding, and traditional metal fabrication techniques. The use of seamless metal forming methods also reduces the need for secondary inspections, such as pressure testing and X-raying, to detect voids and cracks.
Deep Drawn Metal Parts
Deep drawing is ideal for complex cylinders, enclosures, boxes, cases and irregular shapes. The process involves drawing a sheet metal blank around a punch as it's pulled through a die. Meanwhile, the edges of the metal blank are restrained by a blank holder or sleeve. Deep drawing achieves 43% reductions per draw, and greater depths can be formed with multiple draws.
- Amalco makes deep drawn parts ranging from ½ to 24" in diameter
- The maximum depth for deep drawn parts is usually 24"
- We've made some specialty drawn enclosures as deep as 55"
- The maximum blank diameter for deep drawing is 48"
Hydroformed Metal Parts
Hydroforming is ideal for convex/concave domes, covers, and enclosures. The process involves a special pressurized forming chamber, a sheet metal blank, and a punch made in the shape of the desired metal part. The metal blank is placed on top of a ring, which is placed on top of the punch. The hydraulic chamber is then closed over the sheet metal blank and fluid pressure is applied to the top side of the unit. At the same time, the punch is pushed up into the blank and the pressure is increased. This causes the blank to take the shape of the punch.
Hydroforming achieves 60% reductions per draw. Compared to deep drawing, the tooling for hydroforming is usually less expensive, since only a punch and ring are required — while deep drawing requires a punch, die, and a blank holder. When parts are conducive to hydroforming and relatively small quantities are desired, hydroforming is usually the more cost effective solution.
- Amalco makes hydroformed parts up to 15" in diameter
- The maximum depth for hydroformed parts is 10"
- The maximum blank diameter for hydroforming is 21"
Metal Parts Design & Engineering
Let Amalco meet your most challenging metal forming needs with custom solutions or one of our standard product offerings. Contact our Engineering Support Team as early as possible in your product development process — even before your designs are finalized. Our expert engineers can assist you with CAD drawings, alloy selection, and more. We've been making metal parts in the USA for over 100 years, and we've earned a reputation for deep drawing and hydroforming parts other shops have declined to quote.
Secondary Operations (Value Added Services)
- CNC Machining
- Spinning
- Piercing, Blanking & Forming
- Dip Brazing - Aluminum
- Heat Treating
- Painting
- Spot Welding
- Anodizing
- Heliarc® Welding
- Iriditing
- Light Assembly
- Trimming
- Swedging
Materials
- Aluminum
- Nickel
- Stainless Steel
- Monel®
- Hastelloy®
- Brass
- Inconel®
- Titanium
- Copper
- Steel
- Mu Metal
- Special Metals
Quality System (Conforms to MIL-I-45208)
With our MIL-Grade Quality System 
, our commercial customers enjoy the same critical quality control standards that have allowed us to deliver Defense Department contracted product for many years. Amalco employs the latest technologies in its QC inspection processes, and maintains its own QC Manual — maintaining a goal of "Zero Defects on All Products Produced."
Request a Quote
A deep draw, hydroforming, or dip brazing specialist will review your project and recommend the optimal solution. Complete and submit the form below to get started.
Why Do We Choose Amalco?
“Amalco offers a 'one-stop shop'. In the past, our combustion cones were shipped back and forth between several subcontractors to have them perform different production steps. Amalco performs each of these operations at one facility, thereby reducing our cone supplier base from three to one. Now, we coordinate inventory and communications with only one cone supplier, which saves us invaluable time and resources.”
— L.N.,
Director Of Supply Chain Management
for a major manufacturer of waste oil burning heating systems
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