Cold Forging: More Performance, Less Material Waste
Cold forging is the perfect process for durable metal components with complex geometries – completely chip-free. Instead of removing material, it is shaped at room temperature under high pressure. The result: extremely strong, dimensionally accurate, and economically produced parts. Ideal for large series in the automotive, electrical, or medical industries.
Cold Forging: What is it and when does it make sense?
Cold forging is a process of chipless solid forming in which metallic materials are pressed into the desired shape at room temperature under high pressure – completely without material loss. This produces extremely precise, durable components with very good surface quality. Cold forging is particularly useful for high production volumes of about 50,000 parts per year or more, complex geometries, and high demands for dimensional accuracy, repeatability, and strength – for example in drive, electrical, or medical technology.
Our Processes
Cold forging is a proven process of solid forming. The material is plastically deformed in a closed tool by high force. The resulting components impress with high dimensional accuracy, strength, and surface quality – without any machining.
Cup Forward and Backward Forging
The cup forging includes two directions: In cup forward forging, material flow and punch move in the same direction. It is suitable for the production of cup-shaped or sleeve-shaped components with a closed bottom. In cup backward forging, however, the material flows opposite to the punch movement. This variant allows a very strong cross-section reduction of up to 98%, depending on the material, and is particularly suitable for thin-walled hollow bodies.
Typical components: Sleeves, cups, caps with bottom
In double-sided cup forging, the blank is centered and shaped simultaneously from both sides. The remaining material inside is punched out in a further station. For particularly high demands on the inner surface, calibration can be performed. For complex head shapes with excess size, trimming is performed after the main forming.
Typical components: Components with symmetrical or asymmetrical flange shapes, hollow bodies with precise internal geometry
Here, punch movement and material flow run in the same direction. The blank is completely absorbed by the tool and caused to flow through a mold slope. The cross-section reduction is between 55% and 85% depending on the material.
Typical components: Axles, bolts, cylindrical solid parts
This special form of forging utilizes the material’s inherent stiffness. With a flat reducing angle, a cross-section reduction of about 30% can be achieved. Since the component doesn’t have to be continuously guided, it can also be compressed or combined with other processes.
Typical components: Reduced solid bodies with optional additional deformation
This process allows for the simultaneous processing of internal and external geometry. The material flows in the working direction of the press, creating a hollow body. It combines the advantages of full and hollow forging and is ideal for precise and resilient hollow components.
In cross forging, the material flows across the punch movement. The tool opening remains constant throughout the pressing process. The procedure is used for the targeted production of cross-shaped elements – e.g., transverse ribs or hollow shapes that lie across the main axis.
Division of Processes According to Standard
According to DIN 8583-6, cold forging is divided into three basic forms:
- Full forging
- Hollow forging
- Cup forging
Each of These Forms Can Be Used in Three Forming Directions
- Forward forging
- Backward forging
- Cross forging
Our Material Variety
At Walter Schneider, we process a wide range of metallic materials – depending on the component requirements, purpose, and forming strategy. Our specialty lies not only in processing conventional materials but especially in implementing demanding materials that require special knowledge and experience in cold forging.
We manufacture components from:
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Stainless Steel
ideal for corrosion-resistant, wear-resistant components in medical technology, mechanical engineering, or food technology. -
Copper and Lead-free Copper Alloys
for precise, electrically conductive, or hygienic applications. - Special Alloys such as high-strength or temperature-resistant materials for special components.
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Aluminum
light, easily deformable and particularly suitable for weight-optimized solutions. - Tempered Steels, Free-cutting Steels and Other Steels for robust, mechanically resilient parts with a long service life.
Advantages of Cold Forging
High Component Strength
Excellent Dimensional and Shape Accuracy
Material Efficiency
High Productivity in Series Production
Reduced Post-Processing Effort
Versatile Geometries can be implemented
Both rotationally symmetrical and complex asymmetrical parts can be produced. Combination of different extrusion processes in one component is possible.
Typical Concerns About Cold Forging – and Why They’re Unfounded
“With cold forging, the component doesn't work – too complex.”
We often hear these thoughts at the beginning – and regularly disprove them over the course of the project. What initially seems elaborate often turns out, on closer inspection, to be an ideal application for flow forming: rotationally symmetric, high demands on dimensional accuracy, strength, or installation space. Through our design support, we show you early on how even complex geometries can be realized using forming techniques – often more cost-effectively and durably than expected.
“Flow forming? We've never heard of it.”
In fact, the process is still little known among many designers, developers, or purchasers. That’s why we meet our customers exactly where they are: we explain the technical background and show when flow forming is the most economical solution – e.g., compared to machining processes. Particularly in the early design phase, there is a huge optimization potential here.
“The methodology is not very well known in the market.”
That’s true – and at the same time your opportunity. While many competitors continue to rely on traditional milling and turning processes, you secure a real technological advantage with flow forming solutions. Walter Schneider has been one of the few specialists for decades to implement the process in high quality – with self-developed tools, in-house production, and consistent quality assurance.
“The lead times for flow forming are too long.”
The tooling development is indeed more complex than with standard processes – but also only once. After that, you benefit from highly stable series production with low unit costs, high repeat accuracy, and short cycle times. By the way: we rely on quick feedback, digital design, and dedicated contacts already in the development phase – this way, we keep the lead time as short as possible.
Application Areas
- Automotive industry: sleeves, bolts, axle pins, transmission components, connecting elements
- Medical technology: small, precise metal parts, e.g., for surgical instruments or implants
- Bicycle and sports equipment: axles, connecting parts, bushings, damping elements
- Electrical industry: contacts, sleeves, cable grommets, housing parts
- Mechanical and plant engineering: guide elements, mounting parts, complex connecting components
- Chain industry and connection technology: bolts, rivet elements, chain rollers
Your Advantages With Walter Schneider
Custom Component Development With Integrated Tool Design
Technological Advantage Through Cold Forging
Versatile Material Capabilities – Including Hard-to-Form Metals
Whether stainless steel, copper (also lead-free), aluminum, or special alloys: we process almost all standard and even hard-to-form metals. This is particularly valuable for industries with high demands such as medical technology, plant engineering, or the electrical industry, where specific material properties are crucial.