Direct answer: Balford deep draws custom aluminum housings, cans, sleeves and covers for OEM programmes, in 1050, 1100, 3003, 5052 and 6061-series aluminium. Tooling is designed and built in-house, so a new aluminium housing goes from drawing to first-article sample without a third-party die shop in the loop.
Why specify aluminium instead of steel
Aluminium is chosen when weight, thermal conductivity or corrosion behaviour matter more than absolute strength. Typical reasons buyers move a housing from steel to aluminium:
- Weight reduction in automotive and drone assemblies
- Better heat dissipation for sensor and electronics housings
- Natural oxide layer instead of a plating operation
- Lower tooling loads, because the material is softer than steel
- Anodising or chromate conversion as a finish rather than zinc plating
What the deep drawing process changes about aluminium
Aluminium work-hardens less predictably than deep drawing steel, and its lower formability limits how far a single draw can go. In practice this means:
- Draw ratios are kept more conservative than for DC01 or DC04 steel
- Intermediate annealing is planned earlier for hard-temper alloys
- Die and punch radii are generous to avoid orange-peel and tearing
- Lubrication and blank-holder pressure are tuned per alloy, not per drawing
For the underlying mechanics, see the complete deep drawing technical guide and the advantages and process of deep drawing aluminium parts.
Typical aluminium housing applications
- Automotive pressure and position sensor housings
- DC motor housings, end caps and cans
- Electronics and enclosure shells
- Cylindrical covers, cups and drawn sleeves
- IGBT and power-module base components
Finishes available
Aluminium housings can be supplied anodised, chromate-converted, powder-coated or left mill finish. Where a housing carries a plated steel counter-part, the material trade-off is covered in copper vs brass vs aluminium housings.
How to get a quotation
Send the drawing or 3D model with the alloy, temper, thickness, annual volume and any surface or documentation requirement (PPAP, IMDS, material certificate). Use the RFQ checklist for stamped and deep drawn parts so nothing is missed, or go straight to the contact form.