C&L Rivet was contracted by a manufacturer of electronic connectors to design a precision cold heading process for this brass rivet. This part was originally produced in a screw machined process, converting the part to cold heading resulted in considerable cost savings. Custom tooling was designed and fabricated in order to complete the switch. The part was completed on our 2 die 3 blow cold header, starting with Ø 0.1180″ diameter CDA 260 brass round wire. Finished length was 0.8540″, holding tight tolerances of ± 0.002″. We employed a tumble deburring process to completely clean and smooth the rivet slot before packaging. We ship 3 million units per year for this customer, with scheduled monthly releases, and turnarounds of 6-8 weeks.

This rivet was previously manufactured in China as a machined part with drilled holes and a machined slot, costing $0.09 – $0.12 per unit. The new cold headed process resulted in a $0.03 per unit cost, an impressive savings. In addition, the new process resulted in increased production speeds and zero material waste. These are typical benefits of converting to cold heading. For more information about this split terminal pin project or our other value added manufacturing capabilities, please see the table below or contact us directly.

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Cold Heading Highlights of a Brass Split Terminal Pin

Product Description

This brass rivet is used as a pin for a split terminal.

Capabilities Applied/ Processes


  • Part Design – Form, Fit, and Functionality
  • Tooling Design
  • Tooling Fabrication

Cold Heading

Cleaning – Tumble Deburr

Equipment Used to Manufacture Part

Complete part on 2 Die 3 Blow Cold Header

Overall Part Dimensions

Length: 0.8540″

Tightest Tolerances

± 0.0020″

Material Used

COA 260 Brass Wire
Thickness: Ø 0.118″ round wire

In process testing/ inspection performed

Dimensional Inspection, Gage Inspection
Statistical Process Control All Critical Dimensions

Industry for Use

Electronic Connector Industry


3 million per year with monthly releases

Delivery/ Turnaround Time

6 – 8 Weeks First Release

Delivery Location


Standards Met

Customer Specifications

Product Name

Split Terminal Pin

Why did you choose this project to show case?

This part was previously manufactured in China as a screw machine part with drilled holes and a machined slot.
C&L worked with the client’s engineers to convert to a cold headed part. The part originally cost $0.09 – $0.12, but through process conversion the price per piece is $0.03.
Plus no material lost through machining and increased production speeds