In the automotive industry, the reliability of a component does not depend solely on its geometry or mechanical strength. It also depends on the ability to produce it consistently, control its critical requirements and ensure supply stability, especially when dealing with high volumes.
This case study presents the development and industrialisation of an M12 screw for automotive application, produced in high-volume series and subject to demanding requirements in terms of mechanical strength, geometry, dimensional control and supply quality.
More than responding to a specific need, this project demonstrates ETMA’s ability to internally structure a robust production process, mobilising several areas of expertise within its system of 10 Integrated Production Processes.
PROJECT CONTEXT
The project arose through an existing client in the automotive sector, who was looking for an industrial alternative capable of ensuring the production of an M12 screw with specific technical requirements.
The part had already been defined in terms of drawing and final application. The challenge presented to ETMA was therefore not the initial design of the solution, but rather the ability to fully meet the project requirements by creating a stable, competitive internal process prepared for series supply.
In a context where the solution previously available on the market was not able to meet the client’s needs, ETMA was considered due to its technical capacity, the close commercial and technical support provided and, above all, the possibility of bringing together in-house the processes required to manufacture the part.
AN M12 SCREW WITH DEMANDING TECHNICAL REQUIREMENTS
At first glance, a screw may appear to be a simple component. However, when analysed within the context of the automotive industry, it becomes clear that every detail has an impact on the performance, assembly and reliability of the final system.
In this project, the component presented several critical points:
- M12 threading;
- property class 10.9;
- torque requirements;
- high mechanical strength;
- hardness control;
- dimensional control;
- specific geometry, including details at the tip of the part;
- validation through PPAP Level III;
- estimated annual production of around 1 million parts.
The scale of the project, both in terms of the part itself and the expected annual volume, added further demands to the process. In addition to manufacturing the component correctly, it was necessary to ensure production capacity, supply stability, control at every stage and an appropriate response to the agreed deadlines.
ETMA’S RESPONSE: INTERNAL PROCESS, CONTROL AND INDUSTRIALISATION CAPACITY
ETMA’s response involved defining a production route supported by in-house processes, avoiding external dependencies in the critical stages of the project.
Specific forging and rolling tools were developed, adjusted to the geometry required by the client. This stage was essential to ensure that the part could be manufactured with the necessary repeatability and under suitable conditions for high-volume series production.
In the case of forged components, development does not necessarily follow a traditional prototyping logic, as happens in other processes. The focus was mainly on the industrialisation of the part, tool adjustment, validation of the technical requirements and consolidation of a capable process.
The industrialisation time was approximately 14 weeks, during which technical details were clarified, production parameters were defined and the necessary conditions were prepared to ensure a stable transition to series supply.
PRODUCTION PROCESSES INVOLVED
This project highlights the importance of ETMA’s system of 10 Integrated Production Processes, not because all processes have to be used in every part, but because this integration makes it possible to select and internally coordinate the most suitable stages for each industrial challenge.
In this case, the following processes stand out:
The development of specific tooling was decisive in achieving the geometry defined by the client and preparing the process for repeatable production. Forging and rolling tools were developed, adjusted to the technical characteristics of the M12 screw.
The part is produced by cold forging on multi-station machines, a process suitable for the high-volume series production of screws and metal components, with high production rates and dimensional consistency.
This process made it possible to obtain the base shape of the part, while respecting the geometric requirements defined in the technical drawing.
After forging, the part proceeds to the M12 threading operation, a critical stage to ensure the functionality of the component and compliance with the assembly requirements.
As this is a property class 10.9 screw, heat treatment plays a central role in achieving the required mechanical properties, particularly in terms of hardness and strength.
This stage is especially relevant in components subject to torque requirements and high mechanical strength, requiring rigorous control to ensure compliance with the defined specification.
The screw is delivered washed and subsequently oiled, in order to protect the part against oxidation before its final application. In this project, the main purpose of the surface treatment was not to meet severe corrosion requirements, but rather to ensure the appropriate delivery and preservation condition of the component.
As with ETMA’s multi-station processes, the part includes an Inspection / Sorting stage, with 100% control of the critical characteristics defined for the project.
In addition, torque, hardness and dimensional controls are carried out, ensuring that the component meets the technical and functional requirements agreed with the client.
PRODUCTION SEQUENCE
The production sequence defined for this project can be summarised as follows:
This sequence demonstrates the coordination between different internal stages and the level of care required to ensure that the part maintains the required characteristics throughout the entire production process.
HIGH-VOLUME SERIES PRODUCTION AND SUPPLY CHALLENGES
With an estimated annual volume of around 1 million parts, this project required a solid response not only from a technical point of view, but also in terms of production capacity, planning, logistics, raw material and quality control.
The main challenges associated with this volume involved ensuring machine availability, process stability, supply quality and continuous control throughout the different production stages.
In this type of project, industrial robustness is not measured solely by the ability to produce the first conforming part. It is measured by the ability to produce many parts consistently, with control, repeatability and compliance with deadlines.
ADDED VALUE FOR THE CLIENT
For the client, ETMA’s solution mainly represented a reduction in industrial risk.
More than a direct reduction in cost or in the number of suppliers, the value lay in the ability to ensure a stable transition, with compliance with deadlines, close technical support and confidence in the production process.
ETMA was able to demonstrate that it had the necessary expertise to set up, in-house, a robust supply process capable of responding to the technical and operational needs of the project.
The main benefits include:
- greater security in the supplier transition;
- internally structured production process;
- control of critical stages;
- capacity for high-volume series production;
- validation through PPAP Level III;
- close technical and commercial support;
- increased client confidence in larger-sized parts.
CONCLUSION
This M12 screw demonstrates ETMA’s ability to respond to technically demanding projects, combining cold forging, threading, heat treatment, surface treatments and inspection/sorting within an integrated production process.
In a sector where reliability, repeatability and supply stability are decisive, ETMA positions itself as an industrial partner capable of transforming technical requirements into robust, controlled processes prepared for high-volume series production.
With the support of its 10 Integrated Production Processes, ETMA continues to strengthen its ability to develop and produce tailor-made metal components for demanding applications in the automotive sector and other industrial areas.
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