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This section provides an overview for forming processes as well as their applications and principles. Also, please take a look at the list of 10 forming process companies and their company rankings. Here are the top-ranked forming process companies as of December, 2024: 1.Advanex Inc, 2.AHP Merkle GmbH, 3.Dahlstrom Roll Form.
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Categories Related to Forming Processes
A forming process is a processing method using a forming machine that can continuously perform multiple forming processes in a single machine.
Specifically, it refers to the forming process that utilizes plastic deformation such as forging, bending, shearing, and drawing. Products with complex shapes that require multiple processes can be formed using only one forming machine, making this process suitable for mass production.
The forming processes are used in the manufacture of metal products in a variety of fields. Plates and strips are used to manufacture parts such as pins, clips, springs, retaining rings, and bands. Wire rod is used in the production of various coil parts, coil spring parts, and lead wires for electronic parts.
In the forming processes, a single machine can perform multiple forming processes at once. The machine configuration is largely different depending on whether the raw material is a plate or a wire.
Multi-forming is a processing method using a multi-forming machine. Pressing, drawing, and bending can be performed automatically and continuously using plates and strips as raw materials.
The multi-forming machine consists of three main parts. The feeder feeds the material, the stamping unit presses the material, and the forming unit performs the bending and drawing processes with various bending punches.
The wire forming machine used for wire forming processes are processing machine from which the feeding device and stamping device are omitted from the multi-forming machine. Since the raw material is wire, there is no material transfer or pressing process.
The wire is held in the center of the wire forming machine and is bent by several forming tools arranged around its circumference. After all processes are completed, the wire is separated from the coiled material to form a single product.
In the roll forming process, a sheet of metal is passed through a series of rollers with multiple pairs of frames arranged in succession to deform the sheet of metal into the desired shape. The metal strip conveyed from the coiled material is cut to a predetermined size by a cutting machine and then formed by roll forming equipment. These processes are automated and can be produced continuously.
Also, by changing the roller arrangement, it is possible to process various shapes, such as closed cross section shapes. Furthermore, because plastic forming is performed gradually, it is easy to process high-tension materials such as high-tensile steel sheets, contributing to product weight reduction.
As one of the forming processes, the lead forming processes are known to produce leads for electronic components. To connect electronic components to substrates, it is necessary to shape the leads to match the substrates, and lead forming is used in such cases.
Since electronic components are small and difficult to handle, a variety of jig equipment dedicated to lead forming is available.
The merits of the forming processes are that even products with complex shapes can be formed and that it is suitable for mass production, thus reducing labor hours and costs. When similar forming is performed without the forming processes, it is necessary to go through multiple processes to finish the product as a single part. This increases the processing time, the number of die types, and the costs associated with launching a new product.
Another method to increase productivity in press work is the progressive press, in which multiple processes are formed in a single die set progressively. This method greatly improves productivity compared to a single press, but it is limited in the shapes that can be formed. Forming machines, on the other hand, have both press and bending sections in a single machine, making it possible to process even complex bending shapes in succession.
*Including some distributors, etc.
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Weldmac Manufacturing Company, which was started in the 1970s and is located in El Cajon, San Diego, is a manufacturer of precision metal assemblies for its customers. The company offers several services to manufacture the products of the customers, which include assembly fabrication, welding, machining, 3D printing, as well as metal forming. It leverages manufacturing equipment and skills in order to fabricate assemblies that blend in-house machined parts, formed parts, and welding procedures.
Dahlstrom Roll Form, established in 1904 and headquartered in Jamestown, New York, USA, is a manufacturer of customized roll-formed metal products, employing techniques for precise shaping. Its products cater to a wide range of industries, including automotive, construction, aerospace, and renewable energy. The company has received awards like Excellence in Manufacturing (2016) and Innovation in Metal Forming (2019). Additionally, it holds certifications like ISO 9001:2015 for quality management systems and safety.
FINECS CO. LTD. is a Japanese ISO 9001 certified manufacturer of electronic components established in 1969 and based in Nakaniikawa-gun, Toyama. The company produces various standard as well as custom components for electronics such as terminals, pins, connectors, and sockets. It also offers design, precision stamping, semiconductor wire bonding, and cable assembly services for customers with unique project requirements. The company primarily serves clients in the semiconductor, IT, consumer electronics, medical device, and automotive industries.
Advanex Inc, established in 1946 and headquartered in Tokyo, Japan, is a manufacturer of precision springs and pressed components. The company's products include wire springs, flat springs, deep drawings, insert moldings and spring assemblies. It has a prototyping center equipped with five types of NC multi-forming machines that provides customers customization facilities. It provides Finite element analysis services to predict the effect of physical influences such as loads and vibrations on the product.and wire spring calculation program to calculate load or durability of a spring. The company is ISO 9001 certified and follows an inspection system with various equipment for quality checking.
Dudley Industries, established in the United Kingdom in 1942, is a manufacturer and supplier of washroom and hygiene products. The company specializes in providing innovative solutions for commercial and public restroom facilities. With a strong global footprint, it serves a wide array of clients, including businesses, healthcare institutions, and hospitality sectors. Its sustainability and cutting-edge design has earned it an acknowledgment in the washroom equipment industry. Its achievements include numerous industry awards, highlighting its excellence in delivering hygienic, durable, and environmentally responsible solutions.
AHP Merkle GmbH, established in Germany in 1973, is a manufacturer of hydraulic cylinders and components. The company supplies hydraulic solutions for a wide range of industries, including automotive, construction, and manufacturing. It has built a robust international network, catering to clients worldwide. It has achieved significant milestones, including ISO 9001 certification, emphasizing on excellence in hydraulic technology and customer satisfaction. It directs its thinking and potential towards finding solutions that are optimal for the customer, while also breaking new ground. With a priority to continuously improve the efficiency and cost-effectiveness of its products.
KIKUKAWA KOGYO CO., LTD. founded in Tokyo, Japan in 1933 is a manufacturer of architectural interior and exterior metal products. The company's product portfolio includes aluminum, stainless steel, bronze and steel standard and custom-made finishes. The company serves industries such as Oil and Gas, Aerospace and Defense, Automotive and Transportation, Construction, and architecture. The company provides services such as Product Selection Guidance, Engineering Support, and Custom Manufacturing. They also provide custom metalwork services including minimal weld distortions, complex shapes and double curved panels.
Pacific Engineering Corporation (PEC), established in 1961 and located in Ogaki, Gifu, Japan, is a manufacturer and supplier of automotive fuses and precision metal forming machinery. The product range includes multi slow blow fuses, battery terminal fuses, surface grinding machines, CNC floor boring machines, and various others. The company can provide cutting-edge initiatives, such as die production or press forming of high tensile strength steel, to meet a needs in the development of automobiles to ensure safety and environmental functionality related to low fuel consumption and lightweight construction.
Yoshimasu Seisakusho Co. Ltd., established in 1956 and based in Tokyo, Japan, is a manufacturer of aircraft engine and aerospace parts and components as well as precision metal parts. The company specifically designs, manufactures, and assembles precision sheet metal parts and components. Its in-house processes include sheet metal forming, machining, heat treatment, and fabrication. Products made by sheet metal forming include thin ring-shaped parts for rotary machines such as jet engines and thin parts that have complicated shapes and are used at high temperatures.
AMPCO METAL, established in 1914, is a manufacturer and distributor of specialty copper alloys and engineering products like wrenches, knives & scrapers, screwdrivers, hammers, and hex keys used in wear resistance, metal forming, resistance welding, corrosion resistance, and plastic processing, among other uses. The company in Switzerland provides rough cutting and machining, quality control, research and development, technical consultation, and completed machined parts for automotive, marine, oil & gas, aerospace, and general engineering industries.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Advanex Inc |
42.3%
|
| 2 | AHP Merkle GmbH |
11.5%
|
| 3 | Dahlstrom Roll Form |
11.5%
|
| 4 | FINECS |
11.5%
|
| 5 | Weldmac Manufacturing Company |
7.7%
|
| 6 | Dudley Industries |
3.8%
|
| 7 | Yoshimasu Seisakusho Co. Ltd. |
3.8%
|
| 8 | KIKUKAWA KOGYO CO., LTD. |
3.8%
|
| 9 | Pacific Engineering Corporation |
3.8%
|
Derivation Method
The ranking is calculated based on the click share within the forming process page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
Japan
|
5 | 55.6% |
|
United States of America
|
2 | 22.2% |
|
United Kingdom
|
1 | 11.1% |
|
Germany
|
1 | 11.1% |
