Cold Heading

6-station integral forming – Complex geometries - stepped diameters, flanges, undercuts, blind holes, through-holes - are formed in a single dwell cycle. No inter-station handling, no reheat, no scale. The complete metal fiber structure of the raw material remains intact, delivering mechanical properties that machined parts cannot replicate.

Ten new-generation forming lines – capacity and consistency – All ten 6-station platforms are under five years old, with controlled tooling condition and stable precision. High-volume orders run in parallel across multiple cells; maintenance on one unit does not interrupt production. Weekly capacity holds at 420,000+ pieces, supporting seamless scale-up from pilot runs to million-piece production.

Material yield over 95% – Cold heading redistributes material rather than removing it. Scrap is limited to cut-off losses. Compared to CNC turning from solid bar - where material removal can exceed 60% - cold heading delivers substantial material savings at volume, particularly on high-cost materials like copper and stainless steel.

Work-hardened surfaces, as-formed – The cold forming process induces localized strain hardening at critical radii and load-bearing faces. Components emerge with improved surface hardness and fatigue resistance - without requiring downstream heat treatment for base strength. Surface hardness typically reaches HRC22–28 on low-carbon steels and HV300–400 on alloy steels.

Raw material quality control – Cold heading wire/rod stock requires tight surface quality: dimensional tolerance ±0.15mm, out-of-roundness ≤0.10mm, surface crack depth ≤0.07mm. We screen incoming material against these standards to ensure consistent forming results and extended die life.

100% AI visual inspection – Automated vision sorting machines verify every piece for critical dimensions and surface condition. Zero-defect batch release is standard, not aspirational.

IATF 16949-certified facility – Full PPAP Level 3 documentation available - process FMEA, control plans, capability studies - prepared to the same standard we apply to Tier 1 automotive customers. Our material system aligns with YB/T 6106-2023 (wire rods for automotive fasteners).