Custom electronic pins can be manufactured using different techniques, such as swaging or machining. Each method has its own set of advantages and disadvantages. In this article, we'll explore the characteristics of both methods to help you choose the best option for your specific needs.
What is Swaging?
Swaging is a cold-forming process that starts by pulling a continuous metal strip through a precision die to create a seamed tube. The tube is then reduced in size through a series of forming cavities before being cut into individual parts. This high-speed process moves metal rather than removing it, making it efficient and cost-effective. It's ideal for producing small, tubular components with consistent dimensions at a low cost. Swaging can also be used with round or square wire, as well as loose or continuous wire pins.
Key Benefits of Swaging:
- Cost-effective and fast production
- Highly scalable and repeatable
- Uses less material, reducing waste
What is Machining?
Machining involves feeding metal rods through a turning press to produce individual interconnect pins and contacts. While this method allows for greater flexibility, it generates a significant amount of metal scrap, which increases production costs and reduces efficiency.
Key Benefits of Machining:
- Versatile for a wide range of applications
- Capable of achieving very tight tolerances
- Can handle complex and intricate designs
Swaging vs. Machining: A Comparison
When choosing between swaging and machining, several factors should be considered:
Cost Efficiency: Swaging is typically more cost-effective, especially for large volume runs, due to its speed and minimal material waste. Machining, on the other hand, tends to be more expensive because of the higher amount of material removed and longer production times.
Material Usage: Swaging minimizes waste by shaping the metal without cutting it away, while machining often results in significant material loss. In some cases, swaging can reduce material costs by up to 40–80%, depending on the type of metal used.
Precision and Tolerances: Both methods offer precision, but swaging is particularly effective for standard shapes and pin geometries. Machining, however, can achieve extremely tight tolerances and is better suited for complex designs that require multiple steps.
Durability and Strength: Swaged pins often have enhanced strength due to the cold-working process, which increases their structural integrity. Machined pins rely more on the base material’s properties for strength and durability.
When to Use Swaging
- For reducing rods, wires, and tubes
- When remodeling existing products
- For sizing and shaping new components
- When lighter components are required
- In high-volume production scenarios
- When time and budget are critical
- For PCB applications
When to Use Machining
- For complex geometries
- For custom parts with tight tolerances
- During prototyping phases
- When heavier components are needed
Why Bead Uses Swaging
Bead Electronics has been using swaging to manufacture custom pins since 1920. This method combines traditional techniques with modern innovation to deliver high-quality, precise components at a fraction of the cost of machined alternatives. With swaging, we can produce parts in as little as two weeks, offering a fast and reliable solution for our customers.
For example, Bead’s hollow pins weigh 63% less than solid machined pins but maintain the same mechanical and electrical performance. This makes them ideal for applications where weight and efficiency matter.
Learn more about our swaging process—developed and refined over more than 100 years!
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Jiangmen Yingzhihui Electronic Commerce Co., LTD , https://www.yzhprint.com