C&L Rivet was recently contracted to convert a large headed screw machine product to shank ratio through a cold headed process, a cost savings move by the customer. In addition to the cost benefit, the newer process would produce a better performing rivet. This rivet is used in a telecommunications application, as a stop mechanism in mechanical circuit breakers. We designed and co-engineered the necessary tooling and specifics of the new process, maintaining the guidelines for proper dimensioning and tolerance as set by GD&T.

Production was carried out at our ISO 9001:2008 certified facility, where we used our 2 die 3 blow cold header to transform 0.0950″ diameter round wire brass to the specified shape, holding a tight ± 0.0010″ tolerances. Finished dimensions were 0.4980″ long, with an outer diameter of 0.1250″. This product was custom packaged at 10,000 pieces per bag, and shipped to Mexico, China, and areas within the USA. We maintain a yearly shipping schedule of 5 – 10 million parts for this rivet. Typical turnaround time for a project of this magnitude is 6 weeks. For more information about this cold heading project or our other manufacturing capabilities, please see the table below or contact us directly.

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Cold Heading of a Brass Large Head Rivet Project Highlights

Product Description

This rivet is used in mechanical circuit breakers as a stop mechanism when breakers trip.

Capabilities Applied/ Processes

Co-Engineering/Tooling Design
Cold Heading

Custom Packaging (10,000 pcs/bag)

Equipment Used to Manufacture Part

2 Die 3 Blow Cold Header

Overall Part Dimensions

Length: 0.4980″
OD: Ø 0.1250″

Tightest Tolerances

± 0.001″

Material Used

Thickness: Ø 0.095″ round wire

Material Finish

Copper Plated

In process testing/ inspection performed

Dimensional Inspection, Visual Inspection
Statistical Process Control (SPC) All Critical Dimensions

Industry for Use

Telecommunications Industry
Electronic Industry


5 – 10 million per year

Delivery/ Turnaround Time

6 Weeks First Release

Delivery Location


Standards Met

Customer Specifications

Product Name

Shank Ratio

Why did you choose this project to show case?

Screw machine conversion to cold heading with tight tolerance per GD&T