Is it Time to Switch from CNC Machining to Cold Forging

Many design engineers default to CNC machining or turned parts when prototyping custom pins, studs, and special fixings. While machining is ideal for low-volume prototypes and complex geometries, there are scenarios where cold forging can offer advantages in cost, material efficiency, and part performance. Whether to transition depends on your specific design, material, and production requirements, so in this news article, we will cover what specifications you need to consider before making the transition: 

CNC machining removes material tool-by-tool, taking valuable seconds for every part. Cold forging forms metal under pressure within a significantly faster process. However, the economics aren't straightforward. Cold forging requires investment in tooling and dies, which means higher upfront costs at lower volumes. Once production moves into the thousands of units, the per-part cost of cold forging typically becomes more competitive than turned parts, depending on whether your design is suitable for the process.

In CNC turning, a significant portion of your metal bar stock is removed as scrap during machining. Cold forging uses the incoming wire more efficiently, creating less waste material overall. That said, some cold-forged components may require secondary trimming or finishing operations depending on tolerances and functional requirements, so the waste reduction isn't always complete.

The grain flow orientation in a component can influence its mechanical properties. Turned parts cut directly through the grain structure, while cold forging compresses and reshapes grain flow along the component's contours. This can result in improved shear and tensile strength when the material, design, and processing parameters are optimised for this benefit. The actual performance gain depends on the specific alloy, the forming process, and your design; not all applications see the same improvement.

Working with a specialist during the design phase can reveal opportunities to introduce small radii, draft angles, or other geometry refinements that make a component easier to cold-form and produce. However, any design changes must serve the component's functional requirements first. The goal is to find a design that meets performance needs while being producible via cold forging.

Not every component is a candidate for switching. Low-volume production, tight tolerances that are difficult to hold in cold forging, or complex internal features often remain best served by CNC machining. The decision should always balance production volume, tooling investment, design complexity, and performance requirements.

At Clevtec, we back high-performance fastening solutions with nearly a century of manufacturing heritage as the supply chain and distribution division of Clevedon Fasteners Ltd. Operating under ISO 9001:2015 standards, we help OEMs evaluate whether cold forging makes sense for their specific applications, while providing the press insertion machinery, specialised tooling, and vendor reduction programs needed for successful implementation.

Ready to explore whether cold forging is right for your next project? Contact us today to discuss your requirements.