Cold forming is one of the most efficient, cost-effective, eco-friendly metal forging techniques available today. That’s why companies in industries such as aerospace, consumer electronics, medical and automotive make cold forming a key part of their manufacturing processes.

It requires extensive design, engineering and production expertise, along with state-of-the-art equipment and technology, to maximize the cold-forming process. As one of the leading micro cold-forming companies, STS Intelli can provide a reliable solution that will help you meet your manufacturing goals.

How Does Cold Forming Work?

Cold forming takes place at or near room temperature without the application of heat, which saves energy, minimizes material loss and enables much master production speeds. The two most essential tools used in cold forming are a punch press and a die. The punch applies high speed and high pressure to force the metal slug – or blank – which is located within the die, into the desired shape.

Cold Forming vs. Cold Head Machining

Cold forming can actually consist of two separate processes: cold forming and cold head machining. The former entails the use of hydraulic and mechanical vertical presses to punch the metal blank into a shaped component that matches the blank’s volume. During cold head machining, a horizontal press to shape more complex parts. Cold heading is the more volume-specific of the two techniques.

Keys to a Successful Cold-Forming Project

To ensure the best possible outcome when cold forming, it may be necessarily to punch the slug more than once. The second hit will create the proper geometry of the head. It is also essential to introduce the appropriate amount of metal material into the die. Too much material will result in part malformation and may also create a flash that must be removed. Too little material will not completely fill the die, which will produce an insufficient part. The acceptable material volume should not exceed plus or minus 1 percent.

Using Secondary Machining to Complete the Cold-Forming Process

There are various secondary machining techniques that can add features and generally enhance the performance of the cold-forming process. These can include metal finishing methods such as electroplating and electroless plating, which add a protective coating to the cold-formed part for purposes such as corrosion protection, increased wear resistance and enhanced electrical conductivity. Other secondary machining methods include abrasive blasting, shot peening, mass finishing and immersion washing.

Why Choose STS Intelli for Your Cold Forming Needs

Few micro cold-forming companies can match STS Intelli when it comes to reliability expertise. Our cold-forming industrial services are backed by more than 90 years of metalworking experience and a sincere commitment to producing parts of the highest quality. Through the development and implementation of special dies, we can also create custom cold-formed parts or components that meet your unique manufacturing applications.

Contact STS Intelli to learn more about our cold-forming techniques and to receive a no-obligation quote for our cold-forming industrial services.