Custom Cold Heading & High-Volume Metal Fasteners
The Federal Group USA is a premier global manufacturing partner specializing in precision cold heading and high-speed cold forming services. For more than four decades, we have supplied OEM procurement teams and design engineers across North America, Europe, and Asia with high-integrity custom bolts, screws, rivets, pins, and complex stepped shafts.
By leveraging high-speed progressive cold headers, our processes re-align metal grain structures naturally to increase tensile strength and fatigue resistance while eliminating up to 70% of material scrap compared to traditional CNC screw machining.
ISO 9001:2015 Certified Quality: Certified by NSF International, TFG USA delivers 100% built-to-print component accuracy with comprehensive PPAP documentation, optical sorting, and full raw material heat-lot traceability.
Advancing OEM Manufacturing Performance
Our engineering-first approach eliminates supply chain bottlenecks while driving down unit cost for high-volume hardware components.
Optimized Part Design
Our DFM engineers review geometries to modify sharp radii, draft angles, and shoulder transitions for maximum cold former run rates.
Accelerated Lead Times
Progressive multi-die headers produce up to 300 precision parts per minute, ensuring continuous supply for rapid production schedules.
Reduced Material Cost
Near-net forming drastically minimizes raw wire scrap, providing substantial raw material cost savings on expensive alloys.
Zero-Defect Quality
Automated 3D laser inspection and eddy-current testing guarantee dimensional uniformity across multi-million piece shipments.
Comprehensive Cold Forming Capabilities
From micro-fasteners to heavy-duty automotive wheel studs, our global manufacturing network operates 1-die 2-blow up to 6-station progressive headers capable of forming complex head geometries, knurling, upsetting, and forward/backward extrusion.
Case Study: Custom Cold Headed Knurled Fastener
An industrial equipment OEM needed a high-strength SAE 1018 steel fastener with a precision diamond-knurled head and tight shank tolerances. By converting their original design from a turned part to a multi-station cold heading process, TFG USA delivered a production-ready component with enhanced shear strength and flawless knurl definition.
Outcome: Achieved 100% drawing compliance, improved assembly torque retention, and reduced unit manufacturing costs significantly.
Industry-Specific Cold Heading Applications
We deliver mission-critical cold formed hardware tailored to the rigid standards of international industrial sectors.
Agricultural Machinery
Heavy-duty linkage pins, plow bolts, and hardened structural fasteners designed to withstand severe vibration, soil abrasion, and weather extremes.
Construction Equipment
High-tensile Grade 8 track shoe bolts, pivot pins, and heavy-duty frame fasteners engineered for high load distribution and shock resistance.
Heavy Commercial Trucks
Wheel studs, brake mounting pins, engine poppet valves, and custom terminal studs engineered to rigorous automotive safety specs.
Trusted by Overseas Buyers & Engineers
Read genuine feedback from global procurement managers who partner with TFG USA for custom metal manufacturing.
"The Federal Group has demonstrated professionalism and top-tier responsiveness. Communication is fast, pricing is highly competitive, and product quality on custom fasteners has met our strict engineering specs consistently."
"We came to TFG USA with a tight budget and strict project timeline. Their engineering team optimized our cold headed fastener design, delivered tooling early, and exceeded our quality expectations."
"Steve and the TFG USA team are critical to our manufacturing deadlines. Exceptional customer service, prompt communication, and flawless delivery on cast and cold formed components."
Start Your Custom Cold Heading Project Today
Partner with an ISO 9001:2015 certified manufacturer. Send us your CAD drawings or technical prints, and our engineering team will provide a comprehensive DFM review and competitive quote within 24 hours.