Engine mounts, chassis parts, and machined components for assembly lines.
High-strength fasteners, landing gear parts, and structural assemblies.
Forged housings, armor brackets, and mission-critical structural parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Busbar holders, battery pack parts, and lightweight structural enclosures.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Large welded frames, PEB structures, and assemblies for industrial equipment.
Durable transformers built for consistent performance, energy efficiency, and stable power regulation.
Frigate’s industrial-grade enclosures provide durable, customizable protection with efficient thermal management for high-performance applications.
High-performance cables and wires engineered for durability and seamless connectivity across applications.
Custom-built wiring harnesses for secure connections and streamlined installations.
Precision-engineered busbars for efficient power distribution and minimal energy loss.
Robust connectors designed for secure locking, reliable conductivity, and long-term performance.
Diverse solutions covering automotive, electrical, mechanical, and industrial needs with precision-built components.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Frigate CNC Machining offers high-precision, custom solutions for complex casting geometries. Multi-axis capabilities ensure tight tolerances and optimal surface finishes.
Sheet metal fabrication uses laser cutting, punching, and bending for precision.
Frigate Sheet Metal Fabrication utilizes advanced laser cutting and press brake technology for custom casting applications. Tight tolerances, superior welds, and high-strength materials ensure structural integrity.
Injection molding produces high-precision parts with consistent quality.
Frigate Injection Molding delivers custom-engineered parts with micron-level precision and structural integrity. Specialized molds maintain tight tolerances for complex geometries and high-stress applications.
Precision casting ensures accurate, high-quality parts.
Forging services improve material strength with precise tolerances.
Frigate Casting Services provides custom casting with tight tolerances and complex geometries. We enhance material properties using advanced metallurgy, ensuring strength and wear resistance. Our precision methods support high-performance aerospace, automotive, and industrial applications.
End-to-end part production from samples to bulk supply.
Ready-to-use assemblies built to exact fit and function.
Heavy-duty fabrication with high-strength materials for demanding applications. Robust welding for maximum structural durability.
Cold Forging Die Insert must maintain sub-micron dimensional stability over millions of strokes. Thermal fatigue, wear abrasion, and microstructural distortion are mitigated through controlled heat treatment, post-machining nitriding, and CMM-based final inspection. Deviation in critical geometries such as land, cavity, and relief zones remains within ±2–3 µm even under sustained die pressures and elevated temperatures.
Cold Forging Die Insert requires precise interface tolerances to maintain concentric alignment within the die assembly. Fitment geometry is machined with sub-micron accuracy to match holder pockets, reducing relative motion and preventing vibration-induced microfractures. Coefficient of thermal expansion is matched between insert and die block material to prevent dimensional shift during thermal cycling.
Cold Forging Die Insert must resist adhesive wear when used on high-friction materials like stainless steel, Inconel, or dual-phase steels. Surface coatings such as CrN, AlTiN, or DLC, applied via arc-PVD or magnetron sputtering, reduce interfacial shear forces. Coating hardness exceeding 2500 HV and friction coefficients below 0.2 are essential for consistent galling resistance.
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Used to forge high-strength bolts, screws, and rivets with consistent head geometry and shank concentricity in multi-station forming machines.
Cold Forging Die Insert shapes titanium and nickel-based alloy pins, lugs, and brackets with controlled grain flow and minimal machining.
Enables high-volume forming of inner and outer bearing races with uniform hardness distribution and precise radial wall thickness control.
Forms components like rocker arms and cam lobes requiring tight dimensional repeatability and superior surface finish for sliding contact zones.
Cold Forging Die Insert manufactures non-ferrous pins with micron-level diameter control, essential for interference fit and conductivity in connector housings.
Supports forging of complex-shaped coupling and adaptor bodies with uniform wall thickness and defect-free internal flow paths for pressurized systems.
Cold Forging Die Insert is subject to multi-axial stress states with high stress concentration near corner transitions and punch shoulders. FEM-based topology analysis is used to design insert profiles with optimized fillet radii and chamfered load-bearing zones. Materials selected exhibit high fracture toughness (K_IC > 25 MPa√m) to avoid crack initiation under cyclic mechanical impact.
Cold Forging Die Insert experiences rapid thermal cycling that can lead to surface cracking and spalling. Isotropic heat treatment and retained austenite control are critical to preventing thermal fatigue. Tool steel microstructure is refined to eliminate carbide segregation, ensuring resistance to grain boundary crack propagation during continuous high-frequency forging operations.
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Frigate uses CNC machining combined with wire EDM to control die insert dimensions within ±2–3 microns. Every insert is inspected using coordinate measuring machines (CMM) to verify profile accuracy. Thermal distortion is minimized through precision heat treatment and cryogenic stabilization. This process ensures that inserts remain consistent across multiple production batches.
Frigate applies advanced surface treatments like TiCN or AlCrN coatings using PVD techniques for enhanced hardness and low friction. Inserts are also cryogenically treated to improve wear resistance and reduce microstructural stress. Edge conditioning and radius optimization prevent early cracking at high-stress zones. These measures collectively extend die life in high-load forging cycles.
Frigate selects tool steels with high fracture toughness and controlled carbide distribution to reduce crack initiation. FEM simulation is used to refine insert geometry and eliminate stress concentration points. Inserts are tempered multiple times to improve thermal stability and fatigue resistance. These practices reduce failure under cyclic mechanical and thermal loads.
Frigate machines locating features with sub-micron tolerances to ensure concentricity between insert and die block. Each insert is designed with alignment keys or tapered seats for repeatable positioning. Insert profiles are modeled to maintain geometric consistency under axial and radial forces. This ensures accurate part formation in progressive forging operations.
Frigate analyzes the forming load, flow stress, and thermal conductivity of the workpiece alloy before insert material selection. For abrasive materials, high-vanadium tool steels are used; for ductile metals, impact-resistant grades are preferred. Material trials and wear mapping are performed to validate compatibility. This process ensures optimal die performance for each application.
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818, Preakness lane, Coppell, Texas, USA – 75019
10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!