Chipless thread generation in metals using thread-forming screws

Direct Screwing in Metals – Creating Chipless, High-Strength Threads

Thread forming instead of thread cutting creates the foundation for secure, durable, and long-lasting screw connections with reproducible assembly characteristics through full flank engagement.

In direct screwing into metals, thread-forming screws create the thread directly during installation. Instead of cutting the material, thread forming displaces it chiplessly through plastic deformation. A continuous grain structure, work hardening, and full flank engagement ensure exceptional load-bearing capacity. The result is a metric ISO thread with zero clearance and inherent self-locking properties – additional locking elements are generally not required.

Thread forming produces no chips, as the material is displaced rather than cut.

Our Solutions for Direct Fastening into Metals

baier & michels offers a comprehensive portfolio of direct fastening systems for metals, specifically developed for industrial requirements.

Discover our systems here.

Reliable connections in steel, stainless steel, aluminum, and die-cast alloys as well as in multi-material applications

Direct fastening into metals enables threads to be created directly in steel, stainless steel, aluminum, and die-cast materials without additional machining steps. Thread-forming screws create threads in plastically deformable materials. The process also demonstrates its strengths in multi-material applications, enabling reliable and cost-efficient joining of different metallic materials. The thread geometry compensates for angular misalignment during installation and simplifies assembly. The resulting metric ISO threads are standardized and ensure high load-bearing connections. Due to the zero-clearance thread formation and inherent self-locking, additional locking elements according to standards such as DIN 267-27/28 are often not required.

Typical applications of our thread-forming solutions in metals

  • Automotive industry
  • Mechanical and plant engineering
  • Electrical engineering
  • Construction industry
  • Refrigeration and HVAC technology
Wherever cost-efficient and reliable fastening is required, direct fastening into metals offers clear advantages.

Round thread geometry with self-locking – no additional locking elements required

Circular thread geometry as a technological advantage

"Conventional direct screwing systems often use trilobular thread geometries, such as those found in Taptite® screws. These create targeted deformation zones but can lead to localized stress peaks in the component. In contrast, b&m primarily relies on circular thread geometry with full flank engagement, ensuring even load distribution. The result is higher load capacity, reduced material stress, and reliable assembly processes. This principle offers clear advantages in demanding applications and multi-material environments."

Our Solutions for Direct Screwing in Metals

Reliable connections directly in metallic materials – for high performance and maximum process reliability.

Corrosion resistant self-drilling and self-tapping screw for stainless steel applications

b&m-INOXFORM®

Corrosion resistant self-drilling and self-tapping screw for stainless steel applications

Universally usable direct screwing system in all ductile metal materials

b&m-FORM®

Universally usable direct screwing system in all ductile metal materials

Specialized direct screwing system for thin sheet metal applications

b&m-SHEETFORM®

Specialized direct screwing system for thin sheet metal applications

Frequently Asked Questions About Direct Screwing in Metals (FAQ)

Direct screwing into metals refers to a process in which the thread is created directly during screw insertion into the material. This eliminates pre-machining steps such as drilling or thread cutting. The result is efficient, high-strength threaded connections, particularly suitable for industrial mass production and modern fastening technology.

During direct fastening, threads are created in the material through thread forming. The material is plastically displaced without chip formation.
Depending on the material—such as steel, stainless steel, aluminum, or die-cast alloys—the parameters are adapted to ensure precise, reliable, and repeatable screw connections

Thread forming is a chipless process in which the material is displaced, resulting in high-strength threads with continuous grain structure through work hardening.
Thread cutting, on the other hand, removes material to create the thread and is used when the material cannot be plastically deformed.

  • Steel and stainless steel
  • Aluminum
  • Die-cast alloys
Direct screwing also performs reliably in multi-material applications.

Direct thread forming in metals offers a range of technical and economic advantages:
  • Reduced process costs, as steps such as tapping are eliminated
  • Faster assembly through direct thread formation in the component
  • High process reliability due to chipless forming without debris
  • Increased load capacity thanks to work hardening and continuous grain flow
  • Integrated self-locking, often eliminating the need for additional locking elements
This method is therefore particularly well suited for industrial mass production as well as demanding applications in modern designs.

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