Application Profile

Micro Cup with Inside Pedestal

4047 aluminum micro cup with inside pedestal multiple die cold headed part
Micro Cup with inside Pedestal 3D Rendering Micro Cup with inside Pedestal Technical Drawing
Use:  Used as a plug for a micro-miniature electronic device. Pedestal used as a weld point for a weld attachment.
Material:  4047 aluminum.
Manufacturing Method: 
  • Multiple die cold headed part.



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Notable Features: 
  • .125" (3.17mm) diameter cup shape with varying wall thicknesses.
  • Cup shape is formed with a precise (6 degree) outward flare within the tool progression.
  • Pedestal shape incorporated into the inside bottom of the cup.
  • A rare case of cold heading weldable aluminum into a complex morphology.
  • Material waste is minimal.
  • The part is formed from small diameter material and the OD features are formed up.
  • No material removal is needed; scrapless. Machining methods would need to start from a large bar over 1/8" diameter and proceed with heavy material removal. Lots of scrap generated.
  • Stamping/deep draw would create scrap and add to cost.
  • Cold heading gives the advantage of varying the thickness of the wall throughout the morphology of the part (ie: the CROSS SECTION is able to VARY in thickness, ie: the side walls of the cup can be thin, the bottom can be thick, and features like the pedestal can be formed on top of the cup bottom).
  • No cut off tit issues occur with this forming process.
  • Surface finish is very good. No special finishing is needed to produce a high finish. The finish is in the tools.
  • Top surface of the cup walls is precisely flat to within tenths of a thousandth. This can be problematic in the stamping/deep draw process-not experienced in the cold forming method.
  • Production speeds are very high allowing for low production costs, especially on higher quantity piece parts.

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