Custom designed buttons and caps used for diodes, rectifiers, semiconductors, batteries, medical devices and automotive applications

One secret to cold-headed parts manufacturing efficiency and reliability is to build dual functions into a single part to reduce the number of assemblies and create fewer opportunities for failure. Sussex collaborates with its customers to accomplish this as an important objective. Examples are shown below of electronic parts diode cups that combine mount and heat sink, for LED with mount, heat sink, and reflector functions, or reflector and wire lead components, or mount and terminal. All these features are produced as an integral part of a cold forming process.

In addition, Sussex can add unusual shapes to a cold heading part. These include not just difficult-to-accomplish tubular shapes like specialized rivets (often produced by other more expensive and less structural methods), but also out-of-round shapes and features that are not radially symmetric, such as ears on the ID (below). Ordinarily a deep draw-house will be asked to produce this part but may not be able to do it without secondary operations which can lead to problems in conductivity or strength properties. Another uncommon Sussex Wire capability with big potential benefit is the company's ability to produce varying wall thicknesses on inside diameters of cylindrically-shaped parts.