Capabilities & Services

Formedge operates 14 multi-station cold heading machines capable of producing high-volume, precision cold-formed components across a wide range of geometries and materials. Our equipment supports wire diameters from  0.125” to 1.25” and lengths up to 8” long.

Our cold forming process enables:

• Multi-station forming sequences
• Complex head geometries
• Internal and external profiles
• Blind holed forms
• Splined and collared configurations
• Long stroke and large diameter components

Cold heading improves grain flow continuity, increasing tensile strength, fatigue resistance, and structural integrity compared to machined-from-bar components. By forming to net or near-net shape, we reduce material waste and secondary machining, improving cost efficiency at high volumes.

We manufacture cold headed fasteners and structural components for automotive, aerospace, construction, mining, nuclear, and energy applications where strength and repeatability are critical.

Formedge integrates comprehensive secondary operations to deliver finished, ready-to-use components under one roof.

Our equipment includes:

Multi-Spindle CNC Machines
Simultaneous multi-tool machining for reduced cycle time. Ideal for drilling, milling, cross-hole operations, and precision turning in medium to high-volume programs.

Davenport Screw Machines
Multi-spindle automatic screw machines suited for high-volume precision turning and threaded components with consistent repeatability.

ACME Screw Machines
Heavy-duty machining centers for high-speed turning and threading of cylindrical components requiring tight tolerances.

CNC Lathes
Flexible precision turning for simple and complex geometries, capable of holding tight dimensional tolerances and concentricity requirements.

Thread Rolling Equipment
Internal and external thread rolling for UN, UNC, UNF, metric, and custom thread profiles, improving surface finish and mechanical performance.

Additional operations include:

• Cross drilling
• Slotting
• Grooving
• Knurling
• Trimming

By maintaining full secondary integration, we control quality, reduce lead times, and eliminate external process risk.

Why Choose Cold Forming?

1. Net or near net shape
   • Reduce secondary operation
   • Material saving
   • Tight tolerances
2. Improved physical properties
   • Strength (to weight ratio) increases due to continuous, undisputed grain flow
3. Productivity
   • High productivity rate
4. Consistency
   • Maintain dimensional accuracy from part to part
5. Surface finish
   • Fine surface finish without scale
6. Economical
   • Material saving
   • Reduced material wastage (scrapless or little scrap)
7. Wide range of material options
   • Low & medium carbon steel
   • Alloy steels
   • Stainless steels
   • Non ferrous math like copper, brass, AL etc.
8. Environmentally friendly
   • No heat applied prior to forming

Instead of hot forging, casting powdered metal, machining, and stamping, the benefits above make cold forming the most cost effective manufacturing process available for long production runs.

Formedge provides advanced engineering support from initial concept through full production.

Using Siemens NX, AutoCAD, and SolidWorks, our engineering team performs:

• Full tooling simulation
• Material flow analysis
• Forming feasibility studies
• Design for Manufacturability (DFM) reviews
• Failure mode analysis prior to production
• Assembly fit and function review

Through simulation and tooling validation, we can predict potential part failure modes before tooling is built, reducing development risk and accelerating launch timelines.

Our engineering approach supports:

• Rapid PPAP development
• Cost optimization through geometry refinement
• Process capability planning
• Collaborative design reviews with customer engineering teams

We work closely with OEM and Tier suppliers to refine part geometry, improve manufacturability, and ensure structural integrity before the first production run.

Manufactured products include:

• Screws/bolts/hinge pins/rivets/dowels for various automotive application
• Special type flange/collar, inside/outside hex, square profile bolts
• Winged, geared(straight, tapered), satcheted, splined, single side/double side, holed(round, double d, hex, square) formed parts
• Size range capabilities from diameters(0.125”) to 1 ¼ and lengths from (0.250” to 8”)

All required tooling is designed & fabricated in our plant. Many secondary operations are available.

We specialize in providing parts to the following industries:

• Automotive industry
• Engineering industry
• Construction industry
• New development industry
• Mining industry

All tooling is designed, manufactured, and maintained in-house, providing complete control over precision and lead time.

Capabilities include:

• Custom die and punch manufacturing
• Multi-station progression tooling
• Tool steel selection and heat treatment
• Tool maintenance and reconditioning
• Rapid prototype tooling

In-house toolmaking allows us to:

• Shorten development cycles
• Improve dimensional consistency
• Optimize tool life
• Reduce downtime
• Quickly implement engineering changes

By controlling tooling internally, Formedge ensures high repeatability from first article through full production.

Our equipment list:

• Optical comparators (shadowgraph)
• Gauging systems
• Hardness, testing equipment
• Other dimensional measuring instruments

Quality at Formedge is engineered into every stage of manufacturing.

We are certified to:

• ISO 9001:2015
• IATF 16949:2016
• AS9100 (pending)
• N299 (pending)

Our ERP system, JobBOSS², provides full digital traceability from raw material receipt through final shipment. Every lot is tracked, documented, and verified.

Our quality systems include:

• In-line process monitoring
• Statistical Process Control (SPC)
• First Article Inspection (FAI)
• Full PPAP documentation
• Material traceability and lot control

Laboratory and mechanical testing capabilities include:

• Grain flow analysis
• Wedge tensile testing
• Hardness testing
• ASTM standard mechanical testing
• Dimensional inspection using optical comparators and precision gauging systems

We also operate an in-house engineered Vision Sorting Machine for high-speed optical inspection, ensuring defect detection and consistent product quality at scale.

From high-volume automotive fasteners to safety-critical aerospace and nuclear components, our quality systems are designed to prevent defects, validate performance, and maintain compliance with the most demanding industry standards.

Our equipment list:

• Optical comparators (shadowgraph)
• Gauging systems
• Hardness, testing equipment
• Other dimensional measuring instruments