Custom electronic pins can be manufactured using different techniques, such as swaging or machining. Each method comes with its own set of advantages and limitations. In this article, we’ll explore the characteristics of both processes to help you decide which one is best suited for your specific needs.
What is Swaging?
Swaging is a cold-forming process that begins by pulling a continuous metal strip through a precision die to create a seamed tube. The tube is then reduced in diameter through a series of progressive forming stages before being separated into individual components. This high-speed, almost waste-free technique moves metal rather than removing it, making it ideal for producing small, consistent, and cost-effective tubular parts. It works well with round or square wire, as well as loose or continuous wire pins.
Key Benefits of Swaging:
- Highly cost-effective and fast
- Highly scalable and repeatable
- Uses less material, reducing waste
What is Machining?
Machining involves feeding metal rods into a turning press to produce individual interconnect pins and contacts. While this method offers flexibility, it often results in a significant amount of metal scrap, increasing overall production costs. The process typically takes longer and may require more steps, especially for complex designs.
Key Benefits of Machining:
- Versatile for various applications
- Capable of achieving tight tolerances
- Can handle complex and custom designs
Swaging vs. Machining: A Comparison
Choosing between swaging and machining depends on several factors, including your project's size, budget, and performance requirements.
Cost Efficiency: Swaging is generally more cost-effective, especially for large-scale production, due to its speed and minimal waste. Machining, while versatile, tends to be more expensive due to higher material loss and longer processing times.
Material Usage: Swaging minimizes material waste by compressing and shaping the metal, whereas machining often requires cutting away excess material, leading to more waste. 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 ideal for standard shapes and pin geometries. Machining, however, excels when tight tolerances and complex features are required.
Durability and Strength: Swaged pins often have enhanced strength due to the cold-working process. Machined pins, on the other hand, rely more on the base material’s properties.
When to Use Swaging:
- For reducing rods, wires, and tubes
- When remodeling existing products
- For sizing and shaping new components
- When lighter components are needed
- 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 required
Why Bead Uses Swaging
Bead Electronics has been utilizing swaging to manufacture custom pins since 1920. This time-tested method continues 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 efficient solution for a wide range of applications.
For example, our hollow pins weigh up to 63% less than solid machined pins while maintaining the same mechanical and electrical performance. This makes them an excellent choice for weight-sensitive designs without compromising quality.
Learn more about our swaging process—used for over 100 years—to see how it can benefit your next project.
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