Cold Forming: High-precision metal deformation at room temperature

Whether high-strength fastening elements or rotationally symmetrical precision parts – cold forming is the method of choice when dimensional accuracy, material efficiency, and durability are critical. At Walter Schneider GmbH, we shape metals under high pressure – but without heat, without material loss, and without detours.

Shaping without heat – the fundamental principle of Cold Forming

In cold forming, metallic material is plastically deformed by high mechanical pressure – without heating the material beforehand. The forming occurs below the recrystallization temperature, i.e., in a cold state. This cold deformation changes the internal structure of the material: the dislocation density increases, the material hardens, and the grain flow remains intact.

The process generates no thermal stresses – instead, it produces dimensionally accurate, load-bearing components that can be immediately further processed or directly installed. Especially for rotationally symmetrical or geometrically recurring parts, cold forming is a precise and economical method.

Material behavior under pressure – what happens during forming

Cold forming uses targeted pressure at room temperature to controllably plastically deform metallic materials. The force applied to the blank is well above its yield strength – the point at which it becomes permanently deformable. No fracture occurs, but a targeted flow of the metal into the forming tool.

What happens inside

In contrast to warm forming, where the structure is recrystallized by heat, cold forming preserves the original grain flow of the metal. Simultaneously, the structure is condensed by mechanical pressure – leading to so-called work hardening. This internal restructuring results in:

increased flow stress: The material becomes firmer and harder to further deform
increased tensile strength: The component withstands higher mechanical loads
improved fatigue strength: Ideal for alternating loads or vibrations
high dimensional stability: The controlled tool guidance results in minimal springback.

These effects are desired – they lead to significantly longer service life, higher load-bearing capacity, and reduced wear in later use. The targeted influence on material behavior makes cold forming a precise and reproducible process, especially for functional metal parts.

How the process is technically implemented

The actual process begins with the feeding of the blank – e.g., as a wire segment or stamping blank – into a multi-stage forming tool. There, the material is deformed using a punch under high pressure. The material flow occurs either:

forward (in the direction of the punch),
backwards (opposite) or
laterally to the punch stroke – depending on the desired component geometry.

The metal is not machined but pressed under pressure into the target geometry. The forming occurs in closely tolerated tools designed for high repeatability. Each step is precisely guided, so even complex geometries can be mass-produced. Calibration, punching, or trimming can be directly integrated – without downstream processes.

Two processes, two philosophies – Cold Forming vs. Warm Forming

Cold forming is a proven method in massive forming – just like warm forming. Both methods use different physical approaches to shape metallic materials: either by targeted force at room temperature or by forming in a heated state.

Merkmal	Kaltumformung	Warmumformung
Processing temperature	Room temperature (up to approx. 250 °C)	800 – 1,300 °C
Strength	very high due to cold hardening	lower, due to recrystallization
Dimensional accuracy	very high (tenths to hundredths range)	lower, heat-induced deformation possible
Surface	smooth, bright, oxide-free	rough, oxidized, often with scale
Energy requirement	low – no furnace systems required	high, complex heat processes

Conclusion: Cold forming is ideal when dimensional accuracy, high strength, energy efficiency, and reproducible series quality are important.

These materials can be cold formed

Not every material is equally suitable for cold forming – but with the right experience, suitable tool design, and appropriate press control, even demanding materials can be economically processed.

Walter Schneider processes, among others, the following materials:

Stainless Steel: High forming forces, but very resilient and corrosion-resistant

Copper and lead-free copper alloys: Easily formable, electrically conductive, hygienic

Aluminum: Light, can be processed with low forming force – ideal for weight savings

Special alloys: e.g., high-strength or temperature-resistant materials for special applications

Case-hardening steels: For robust components with high process stability

Advantages of Cold Forming

100% material utilization

In cold forming, the entire volume of the workpiece is transformed into the desired geometry. No chips are produced, no waste. This results in an economic advantage, especially with expensive materials such as stainless steel or lead-free copper – particularly in mass production.

Highest component strength through work hardening

Since no heating occurs, the original grain flow of the metal is retained. Simultaneously, the microstructure is compacted through mechanical pressure – the so-called work hardening. The result: superior fatigue strength, high wear resistance, low risk of microcracks or predetermined breaking points.

Dimensional accuracy up to hundredths of a millimeter

Cold forming allows for extremely tight tolerances – often in the range of 0.03–0.05 mm, depending on the material and geometry. Our CAQ-controlled processes ensure consistently high repeatability across millions of components.

Elimination of many subsequent processes

As cold forming is net-shape capable, subsequent processing is often unnecessary. Grinding, milling, or deburring can either be completely eliminated or integrated into the forming process. This shortens lead times and reduces manufacturing costs.

More energy-efficient than thermal processes

Cold forming doesn’t require oven technology, gas heating, or annealing processes. This significantly reduces energy needs – a benefit that is economically advantageous as well as noticeable in terms of CO₂ balance and sustainability goals.

Areas of application – Where cold forming makes a difference

Cold forming is used wherever components need to be produced in large quantities, with high dimensional accuracy and permanently load-bearing properties. The process is particularly suitable for recurring geometries and precise functional parts made from demanding materials.

Industries and typical applications:

Machine and plant engineering
Fastening elements with defined clamping force, precisely fitting guide bushings, precise bearing components
Electrotechnology
Hollow bodies and contact parts with high conductivity, structured housing elements for connectors
Medical technology
filigree components made of stainless steel or lead-free copper – sterile, robust, precisely manufactured
Bicycle and sports equipment manufacturing
weight-optimized axles, damping structural parts, rotationally symmetric components
Connection technology & chain industry
Rivet bolts, rolls, and profiles with tight tolerances and high repeatability

Whether filigree or massive, rotationally symmetric or combined – cold forming delivers stable and precise results. The unit costs remain economically attractive even for high demands.

Technical depth, short paths – Cold Forming at Walter Schneider

We do not think of cold forming as a standard process, but as part of an integrated, production-oriented solution. From design to series production, we support our customers with technical expertise, industry-specific experience, and a clear commitment to quality.

What sets us apart:

Own toolmaking

Every forming solution is based on precisely fitting tools. We develop, manufacture, and test these in-house – tailored to material, geometry, and target quantity.

Design support included

Our engineers step in early when needed. This allows components to be designed process-secure and economically from the start.

Expertise in special materials

Lead-free copper, stainless steel, hard-to-form alloys – we have the necessary experience to process these materials stably.

Process-technically flexible

By combining forward, backward, and cross flow pressing, we realize even complex or asymmetric geometries in one pass.

Quality made measurable

Integrated in-process controls and digital CAQ systems ensure consistently high component quality – documented, traceable, reliable.

Contact

You have a part, a drawing, or a specific need?
We analyze whether and how your requirements can be implemented through cold forming – directly, without obligation, and with technical feedback. Because good consultation doesn’t start with a form – it starts with a conversation.