Where Cold Forming Shows Its Strength
Real Projects.
Proven Engineering Performance.
These case studies show how our cold forming expertise transforms technical requirements into robust and cost-efficient series production solutions.
4 Case Studies
Real Engineering Improvements for Our Customers
Four Case Studies – Engineering Improvements at a Glance
Costs down. Weight down. Complexity out. Efficiency up.
This is how cold forming improves real customer components.
Through targeted design adjustments and cold forming expertise, complex components become leaner, stronger and more efficient.
Selected Case Studies:
Lower Cost. Less Complexity
Significant Weight Reduction
Cost Reduction in Series Production
Cost Efficiency and Secure Supply
Reduction of Complexity
Pawl for Car Locks
About the Locking Pawl
A pawl in a car lock secures the locking mechanism in a defined position and ensures reliable engagement of the locking system.
Its Main Functions
• Fixing the locking mechanism in position
• Preventing unintentional opening
• Protecting against tampering and theft
The pawl therefore plays a key role in the security and functional reliability of the lock.
The Challenge
Previously, two separate components from different suppliers were required. This resulted in additional assembly effort, higher costs and potential quality risks.
Our customer developed the idea of combining both parts into a single component and first turned to another supplier. However, the concept could not be realised there.
The Solution
Using a multi-stage, high-precision cold forming process, we succeeded in producing the optimised pawl as a single component. Today, millions of these parts are manufactured reliably in series production.
For additional noise decoupling and wear protection, the component receives a plastic coating as well as the proven Delta-Seal surface treatment.
The result is a robust and cost-efficient solution that improves both reliability and manufacturing efficiency.
Weight Reduction
Axle for Premium Luggage Trolleys
About the Axle
The axle is used in the castors of a premium luggage brand. The manufacturer is internationally recognised for lightweight products that combine high stability, durability and travel comfort.
For this brand, product quality is essential – from sophisticated design to reliable functionality. The true value of these qualities becomes particularly evident when travelling – especially when things get hectic.
The Challenge
The axle must therefore be extremely lightweight while maintaining high mechanical robustness.
Until now, the axles had been manufactured from steel. However, when developing lightweight systems, every gram matters.
The Solution
Our engineering team analysed the functional requirements of the component in detail. The reason steel had previously been used was its ability to provide the required hardness and structural stability.
Based on this insight, we optimised the manufacturing concept and introduced a lightweight aluminium solution – without compromising the required hardness and durability.
This creates a decisive advantage for the end customer: a renowned luggage manufacturer whose USP lies in the exceptional lightness and robustness of its products.
Reduction of Costs
Axle for Automotive Central Locking Systems
About the Axle
The axle is a key component responsible for transmitting movement within the locking mechanism of an automotive central locking system.
The Challenge
Previously, the axle was manufactured as a turned stainless-steel part.
However, the machining process resulted in comparatively high production costs, making a more economical solution necessary.
The Solution
The component was redesigned for cold forming and manufactured from aluminium to unlock further optimisation potential.
Targeted heat treatment ensures the required component strength despite the lightweight material.
The result is a significantly more cost-efficient component while maintaining the necessary functional reliability.
Economy Meets Secure Supply
Copper Threaded Studs for E-mobility
Challenge
The secure and cost-efficient procurement of a critical component was central to the customer’s requirements. The objective was to localise the supply chain and reduce the risk of bottlenecks without increasing costs.
The copper bolt had previously been manufactured as a turned part. However, its profiled rivet pin made the turning process complex and inefficient. Cold extrusion offered a far more efficient manufacturing approach.
In the final product, the bolt is plastic-coated and functions as a sealing element in the injection moulding process.At the same time, different tolerance zones had to be precisely maintained along the entire length of the component.
Solution
MN Kaltformteile benefits from its strategically advantageous location within Europe’s key domestic and export markets. By combining cold extrusion with precise downstream processing – particularly internal thread forming – we were able to offer the customer a significantly more cost-efficient alternative to turned parts.
The manufacturing process was changed from machining to forming, resulting in several important advantages:
• the formed thread provides higher strength because the material fibre flow remains intact
• material loss is reduced, creating both economic and sustainability benefits – particularly important when working with copper
• thread forming produces a smoother surface and improves wear resistance, increasing component service life
In addition, our materials expertise enabled us to optimise the electrical conductivity of the component by adjusting the material composition.
As a result, the customer benefits not only from reliable and cost-efficient procurement, but also from improved performance of the end product.
Where Industry Leaders Place Their Trust
Less Is More. Where Others See Limits, We Engineer Solutions.
Let’s Improve Your Component Together
- Volker Wolf, Commercial Managing Director / Sales Manager
