Why Cold Forming?


Cold Forming: A Cost-Benefit Comparison

New product development (NPD) teams are always looking for a competitive edge that will allow them to make their electronic devices smaller, appliances more reliable, vehicles safer, or instruments more precise. These products often call for highly engineered metal components on an increasingly miniaturized scale, and the demand for these miniature and micro metal components is accelerating. Those developing such products have a variety of choices in sourcing these components, seeking to meet critical functional specifications to assist with design for manufacturing (DFM), design for assembly (DFA), quality and cost.

Weighing the available processes against one another according to cost-benefit criteria by which they are typically assessed brings to the forefront one process that is often overlooked.

What is Cold Forming?

Cold forming is the application of force with a punch to a metal blank staged in a die.


The force exceeds the alloy’s elastic limit, causing plastic flow until the metal blank assumes the shape bound by the punch and the die. As the name implies, this method of forming is achieved by force alone, forgoing the application of additional heat or cutting and shearing.

When machining a part, grain flow of the material is interrupted as the original material is removed to form the part. Through the cold forming process all original material is used causing a restructuring of the material grain as the part is formed. This results in improved tensile strength as compared to manufacturing techniques.

Advantages:

While there are other ancillary benefits to utilizing cold forming and heading, there are five principle advantages versus other manufacturing techniques.

Click on each link for more detail:



Sussex Wire specializes in technical collaboration and manufacture of micro-miniature metal parts. We make sure customers see the maximum benefit of cold forming while meeting the specific critical tolerances of their project. View our Case Studies to see how we’ve helped customers get the most out of their project.

What types of projects can utilize cold forming?

Many part types can be made using cold forming and cold heading technology. Typical part includes: fasteners, screws, nuts, bolts, electrical contacts, and rivets. In addition to these parts, many other custom applications can be created and will benefit from this manufacturing technology.

Projects requiring the following often use cold forming as an ideal solution:

  • Mission critical applications
  • High volume requirements
  • Correction of part failures
  • Added material strength required
  • Tight tolerances and critical specs


Cold forming can be used in many project types with a broad range of shapes including: threads, knurls, heads, chamfers, grooves, taper and undercuts.

Features that cannot be made with cold forming or heading can be made utilizing other secondary in-house capabilities such as: rolling, threading, pointing, bending, or, annealing.

See our manufacturing technology chart to see how Cold Forming compares to other manufacturing technologies.





Sussex Wire specialized in custom applications for micro-mini components and technical collaboration across many markets. See the markets we serve or, contact us today about your current and future projects.

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