Additively manufactured polymer punches for deep drawing: performance assessment and infill design

Purpose This study aims to investigate lightweight polymer punches made by material extrusion as an alternative to metallic tooling for aluminum deep drawing. Design/methodology/approach The methodology is structured into two phases. First, a screening campaign evaluates the effect of infill pattern (triangular, gyroid) and density (35%, 50%) on dimensional accuracy and punch integrity through 10 consecutive forming cycles. Findings The screening experiments demonstrated that triangular infill ensured superior dimensional stability compared to the gyroid configuration, while higher infill density increased stiffness and reduced geometric deviations. Research limitations/implications This study is limited to cylindrical cups in Al1050 formed using SCF-Nylon punches produced by material extrusion, with only two infill patterns and two density levels evaluated. The results, therefore, cannot be generalized to other polymers, reinforcements, sheet materials or more complex geometries. Practical implications The results demonstrate that additively manufactured polymer punches can reliably support prototyping and small-batch deep drawing, offering a cost-effective and lightweight alternative to metallic tooling. The study shows that appropriate infill design – specifically triangular infill at moderate density – provides sufficient dimensional stability while significantly reducing material consumption and printing time. Social implications By enabling faster, cheaper and more sustainable tooling, this study supports broader adoption of additive manufacturing in industry, contributing to resource efficiency and reduced environmental impact. The use of lightweight polymer tools lowers material consumption and energy requirements compared to conventional metal tooling, aligning with circular economy principles. Originality/value This study provides one of the first systematic evaluations of how infill pattern and density influence the performance, deformation and wear of polymer punches in deep drawing. Unlike previous works, it combines a controlled screening phase with a 99-cycle batch campaign, enabling detailed insight into both short-term and progressive tool behaviour.