What is Swaging?
Swaging is a cold-forming process that begins by pulling a continuous metal strip through a precision-engineered die to create a seamed tube. The tube is then gradually reduced in diameter through a series of forming cavities before being cut into individual components. This high-speed process involves shaping the metal rather than removing it, making it highly efficient. It’s ideal for producing small, tubular metal parts with consistent dimensions at a lower cost. Swaging works well with both round and square wire, as well as loose or continuous wire pins.Key Benefits of Swaging:
- Cost-effective and fast production
- Highly scalable and repeatable
- Uses minimal material
What is Machining?
Machining involves feeding metal rods into a turning press to produce individual interconnect pins and contacts. This process typically generates a significant amount of metal scrap, which increases the overall cost. While it offers flexibility, it tends to be slower and less efficient compared to swaging.Key Benefits of Machining:
- Versatile and adaptable
- Capable of achieving tight tolerances
- Supports complex and intricate designs
Swaging vs. Machining: A Comparison
When choosing between swaging and machining, consider the following factors:Cost Efficiency: Swaging is more cost-effective, especially for large-volume orders, due to its speed and low material waste. Machining, on the other hand, produces more scrap and takes longer, increasing costs.
Material Usage: Swaging minimizes waste by compressing and shaping the metal, while machining often involves cutting away material, resulting in higher waste. Swaging can reduce material costs by 40% to 80%, depending on the type of material used.
Precision and Tolerances: Both methods can achieve high precision, but swaging is particularly effective for standard shapes and pin geometries. Machining, however, excels when extremely tight tolerances are required and may involve multiple steps to achieve the desired result.
Durability and Strength: Swaged pins often benefit from the cold-working process, which enhances their strength. Machined pins, on the other hand, rely more on the properties of the base material.
When to Use Swaging
- For reducing rods, wires, and tubes
- For modifying existing products
- For sizing and shaping new components
- When lightweight components are needed
- For high-volume production
- When time and budget are critical
- For PCB applications
When to Use Machining
- For complex geometries
- For custom parts requiring tight tolerances
- For prototyping
- When heavier components are required
Why Bead Uses Swaging
Bead Electronics has been using swaging to manufacture custom pins since 1920. This innovative approach combines an old technique with modern efficiency, offering numerous benefits. Swaging allows us to produce high-quality, high-precision pins at a fraction of the cost of machined alternatives, often within just two weeks. For example, our hollow pins weigh 63% less than solid machined pins, yet they maintain the same mechanical and electrical performance. Learn more about our swaging process—used for over 100 years—to see how it can benefit your next project.The mixing machine is applicable to mix dry granule material for pharmacy and other relative industries.The machine has the features of the special construction, high effect, no dead angle, uniform mixture. The machine can also increase to blend the function compulsorily. It can mix thin powder and more than two form powders including the materials that contain water. It can get the good result of admixture (meaning that little admixture additives).
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