Swaging is a forming process commonly applied on metal wires, pipes and strips to change the dimensions of the profile by forcing them into dies as a cold or hot working process. To achieve it, different methods are used, including extrusion through a die and the use of two or more rotary dies from the outside, to reduce the diameter of a section.

An important characteristic of this process is that, although there is a reduction in the diameter, no material is lost as it happens with other manufacturing processes such as machining.

There are different applications for this process, for example:

  • As part of forging a piece with the intention of making it more beautiful or to make it fit for the desired purpose.
  • To create permanent joints between pipes and fittings.
  • In electronics as a substitute of welding.

Moreover, a common application of this process is creating collars on tubes, bars or wires with a round section, also known as collar swaging. Collars are used to provide locking power to a non-threaded part such as a bolt or to increase the locking power of threaded ones.

Stage I Stage II Stage III

Stage IV + End stage


Diameter 1/2“, 2 sec. cycle time, series runs from 20,000 parts, finished part falling out, power requirement approx. 30 kW.

Combination with other processes

Many applications require more than swaging to generate the part and get it ready for market. Some common applications involve parts that require bends, threaded sections, flat sections with holes for fasteners, together with collar swaging and, perhaps, other processes.

Traditionally, each process is performed independently requiring specific tooling (presses and dies) and operators for each of them. Of course, these requirements result in higher costs and reduced efficiency, which in turn means less productivity, a longer time to market and lower profitability.

To avoid those negative aspects when needing to perform swaging combined with other processes on the same piece, Schmale machines provide fully automated solutions that integrate more than one process as required, including bending, threading, flattening and swaging, allowing you to achieve a high level of efficiency and productivity.

The process begins where a wire with a diameter of up to 1" is fed into the tool set by automatic servoelectric feeders. Then the wire goes through the different processes where an arrange of automated benders and presses generate the expected results.

The entire cycle for the shown sample part only takes 2 seconds, with series runs beginning at 20,000 parts, which clearly represents an enormous increase in efficiency and productivity and a significant reduction in the time to market, meaning that the profitability of your business will be higher.

To have a better view of the process please refer to the pictures and videos.

If you are looking for an automated swaging solution, or you have any further question, please do not hesitate to contact us and we will gladly help you.


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