This study investigates the effects of the size of copper sheets on the plastic deformation behavior in a microscale deep drawing process. Tensile tests are conducted on the copper sheets to study the flow stress of the materials with different grain sizes before carrying out the microscale deep drawing experiments. After the tensile tests, a novel desktop-sized microscale deep drawing system is used to perform the microscale deep drawing process. A series of microscale deep drawing experiments are subsequently performed, and the experimental results indicate that an increase in the grain size results in the reduction of the deformation load of the copper sheets due to the effects of the surface grain. The results also show that the blank holder gap improves both the formability of copper sheets and the material flow.
