C&L Rivet was commissioned by a customer in the glass seal industry to design and fabricate a cold-headed version of their screw machined weld stud. This re-design would mean improved surface finish and product performance, as well as material and production cost savings. Our experts collaborated with their engineers to produce the new design and tooling for this upgraded process.

Process a 0.0240″ diameter…+/- 0.0010″ throughout. Completed dimensions were 0.0370″ long and 0.0460″ in diameter Kovar wire to the specified size, holding tight tolerances of ± 0.001″ throughout. Completed dimensions were 0.0370″ long and 0.0460″ in diameter, with a 16 RMS finish. To provide a total manufacturing solution, the parts were cleaned and packaged for shipping. During production, optical and dimensional inspections were carried out to ensure accuracy; in addition this part was subjected to our internal quality control measures. Turnaround time for this project was 6 – 8 weeks, with an annual shipping schedule of 500,000 units. For more details about this Kovar weld stud project, or how we develop cold-headed processes for screw machined parts, please see the table below or contact us directly.

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Highlights from the Engineering of a Kovar Weld Stud

Product Description

These parts are used in the electrical contact applications

Capabilities Applied/ Processes

Co-Engineering/Tooling Design
Cold Heading


Equipment Used to Manufacture Part

2 Die 3 Blow Cold Header

Overall Part Dimensions

Ø 0.0240″ diameter
+/- 0.0010″ Length

Tightest Tolerances

± 0.001″

Material Used

Kovar Wire
Thickness: 0.024″ dia round wire

Material Finish

16 RMS

In process testing/ inspection performed

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

Industry for Use

Glass Seal Industry Electronic Contacts


500,000 / Year

Delivery/ Turnaround Time

6 – 8 weeks

Delivery Location


Standards Met

Customer Specifications, 2D CAD Drawing

Product Name

Weld Stud

Why did you choose this project to show case?

Originally Screw Machined Part. Tool designing with customer’s engineering team to convert to a cold headed process.