Capability

Tooling & Die Shop

The die decides the part — so the die is made here

In-house diesPunchesFast iterationDressing schedule

Precision screw family produced from in-house heading dies

Tooling & Die Shop · Bekasi plant

Process overview

The die decides the part — so the die is made here

Every characteristic of a cold-formed screw is set by the die that formed it: head diameter, head height, recess geometry, shank concentricity and the radius under the head. Once the die is cut, the part is what the die says it is. That is why tooling is the first step in the process rather than a supporting activity.

Making dies in-house changes the development loop. When a sample needs a different head height or a recess that drives more cleanly, the geometry can be adjusted and re-tried within the development cycle instead of being sent out and scheduled behind other work. The same shop also maintains production tooling: punches are dressed on a fixed interval rather than replaced after a defect appears, because at micro sizes a worn punch produces cam-out long before it produces a visible failure.

Step by step

How the process runs

Each step has a defined control point. The sequence is not arbitrary — changing it changes the result.

Part and process review

The drawing is reviewed against what cold forming can produce — draft, radius, wall thickness at the recess, and the material grade the part needs.

Die design

Die and punch geometry are laid out from the head form, the drive recess and the shank reduction ratio, so that material flows into the head instead of being forced.

Die manufacture

Dies are machined and finished in-house, which keeps the geometry iteration inside the plant during development.

Trial and sample

Sample parts are formed and measured, then adjusted until the parts match the drawing and drive cleanly in the customer bit.

Production tooling maintenance

Punches are dressed on a defined interval and inspected, so recess wear is controlled before it becomes a cam-out problem on the customer line.

Specification

Process window and capability

The numbers below define what the process can hold repeatably. They are not laboratory bests.

Tooling scope

Heading dies and punches for cold-formed screws

Where made

In-house die shop

What the die sets

Head diameter, head height, recess geometry, shank concentricity, under-head radius

Development benefit

Geometry changes made inside the plant during sampling

Maintenance

Punch dressing on a defined interval rather than on defect

Design constraint

Minimum wall thickness at the recess, drive style, material grade

Equipment

What the line is built on

Capacity figures are per machine and assume a standard part. Complex geometry reduces throughput.

Equipment	Specification
Die and punch manufacture	In-house machining and finishing of heading tooling
Tool maintenance	Scheduled punch dressing and inspection
Sample evaluation	Dimensional measurement and drive-fit trial before release

Process control

What is checked, and when

A control that is not recorded is not a control. Each item below generates a record linked to the lot code, retained for the programme duration.

Quality & certifications

Die geometry verified against the drawing before release to production

First-off sample measured and drive-tested

Punch wear monitored against the dressing interval

Recess geometry checked with pin gauge and vision

Head height and diameter measured on the formed part, not on the die

Tooling records kept so that a part can be reproduced from its die history

Questions

Tooling FAQ

Practical questions from sourcing and engineering teams.

Considering a process change? If a tolerance or finish is not achievable on our current line, we will say so before quoting rather than after the first lot.

Why does in-house tooling matter to a customer?

Because it shortens the loop between a sample and a design change. If a head is 0.1 mm too tall or a recess drives badly, the geometry can be revised and re-tried inside the plant rather than being queued at an outside toolmaker.

Does a new part always need a new die?

Not always. Where an existing die produces a head and shank that match the new drawing, only the length or the thread may need to change. That is evaluated during the drawing review before tooling cost is quoted.

What limits what a die can produce?

Minimum wall thickness at the recess, the reduction ratio between wire and shank, and the material grade. A deep recess in a small head leaves very little material around it, and that is a die design constraint, not a machining one.

How is punch wear controlled?

By dressing on a fixed interval. At micro sizes a worn punch does not fail visibly — it produces a recess that cams out on the customer line, which is a much more expensive way to find out.

Related capabilities

What happens before and after

These processes are usually sequenced with the one above.

Capability

Cold Forging

Single- and multi-station cold heading forms the screw from wire, so the grain follows the part contour and no material is machined away.

Capability

Thread Rolling

Rolling reforms the grain along the thread flank instead of severing it, producing a stronger thread with a smoother surface and no chip waste.

Bulk micro screws prior to optical sorting

Capability

Optical Sorting & Packing

Vision and laser sorting inspects every screw for head, recess and dimensional defects, and packs the accepted parts in the format the customer feeder needs.

Need tooling for your part?

Send the drawing and the annual volume. We will confirm feasibility, tolerance and lead time in the quotation.

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