Swaging vs. Machining: Choosing the Right Method for Custom Electronic Pins

Custom electronic pins can be produced using various manufacturing techniques, such as swaging or machining. Each method has its own set of advantages and limitations. In this article, we’ll explore the distinct characteristics of both processes to help you choose the best option for your specific needs.

What is Swaging?

Swaging is a cold-forming process that begins with a continuous metal strip being pulled through a precision-engineered die to create a seamed tube. The diameter of the tube is then gradually reduced in a series of forming cavities before being cut into individual components. This high-speed, nearly waste-free technique involves shaping the metal rather than removing it, making it ideal for producing small, tubular metal parts that are both dimensionally accurate and cost-effective. Swaging can also be applied to round or square wire, as well as loose or continuous wire pins.

Key Benefits of Swaging:

  • Highly cost-effective and fast
  • Consistent and repeatable results
  • Uses minimal material
Bead Electronics Swaging Image

What is Machining?

Machining involves feeding metal rods through 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 of production. While machining offers flexibility, it is generally more expensive and slower compared to swaging, especially for large-scale manufacturing.

Key Benefits of Machining:

  • High versatility
  • Can achieve very tight tolerances
  • Capable of handling complex designs

Swaging vs. Machining: A Comparison

When choosing between swaging and machining, consider the following factors:

Cost Efficiency: Swaging is usually more cost-effective, especially for large volume runs, due to its speed and low 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 compressing and shaping the metal, while machining often involves cutting away excess material, leading to more waste. Swaging can save up to 40–80% in material costs depending on the type of metal used.

Precision and Tolerances: Both methods can produce precise parts, but swaging is particularly effective for standard shapes and pin geometries. Machining, however, excels in achieving extremely tight tolerances, though it may require multiple steps.

Durability and Strength: Swaged pins often have improved strength due to the cold-working process. Machined pins, on the other hand, rely more on the inherent properties of the base material.

When to Use Swaging:

  • Reducing rods, wires, and tubes
  • Modifying existing products
  • Shaping and sizing new components
  • When lighter components are required
  • For high-volume production
  • In situations with tight timelines or budgets
  • For PCB applications

When to Use Machining:

  • Creating complex geometries
  • Producing 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. It's an innovative approach to an age-old process, offering numerous benefits. Swaging allows us to produce high-quality, high-precision pins at a fraction of the cost of machined alternatives, often in as little as two weeks. For example, Bead’s hollow pins weigh 63% less than solid machined pins but maintain the same mechanical and electrical performance. Learn more about our swaging process — a technique we've refined over more than 100 years!

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