Fabrication Processes at Rollyu • Tapping & Threading

Tapping and Threading in Sheet Metal Fabrication

In sheet metal fabrication, creating internal threads allows for secure assembly of enclosures, brackets, panels, and structural frames. Depending on material type, thickness, and application, two primary methods are used:

1️ Cut Tapping (Conventional Tapping)

• A cutting tap is used to remove material and create internal      threads, suitable for most metals.

• Suitable for most metals, including aluminum, carbon steel,      stainless steel, titanium, and copper alloys.

• Delivers precise threads for thin and thick materials alike.

• Commonly used for precision enclosures, mounting plates, and      robotic frames where assembly strength and repeatability are critical.

2️ Thread Forming (Roll Tapping)

• Cold-forms threads without removing material; improves strength      in ductile materials like aluminum, brass, and soft steels.Cold-forms the      threads by displacing material without cutting.

• Ideal for ductile materials like aluminum alloys, soft steels,      brass, and copper.

• Produces stronger threads due to work-hardening and      uninterrupted grain structure.

• Reduces the risk of chip contamination, making it well-suited      for medical, semiconductor, and cleanroom environments where loose      chips are unacceptable.

• Excellent for thin-wall sheet metal parts where thread strength      must be maximized in limited material thickness.

Suitable Materials for Tapping & Threading

Threading Standards & Capabilities

• Metric Threads (M1.0 – M50)

• Unified Threads (UNC, UNF, UNEF)

• NPT, BSP, and custom pipe threads

• Helicoil (thread insert) preparation and installation

• Thread tolerances per ISO, ANSI, ASME, and DIN standards

• Machine screw sizes down to #0-80

Quality Control for Threads

• Go/No-Go thread plug gauges

• Thread ring gauges for external threads

• Visual inspection under magnification

• Class 2B / 3B / 2A / 3A tolerances for critical threads

• Material-specific process controls to avoid galling or thread      tearing

Why Tapping & Threading Matter

Precision threads are essential for:

• Surgical device assemblies

• Semiconductor fixture components

• Automation brackets and adjustment mechanisms

• Aerospace sensor mounts

• Medical robotics housings

Improper thread quality can lead to fastener failure, torque inconsistencies, misalignment, or long-term fatigue issues — especially in industries where every component must meet strict reliability, cleanliness, and assembly repeatability requirements.

Rollyu Precision Advantages

Multi-process CNC threading integration (turning, milling, tapping)
In-house tool management for micro-threads and special pitches
Full documentation & traceability under ISO 9001 & ISO 13485
Specialized tapping for medical-grade aluminum, stainless, titanium
High repeatability for both prototype and production runs

Thread quality directly affects assembly strength, torque consistency, and long-term reliability—especially in thin-wall sheet metal parts.

If you have questions about tapping method selection, thread strength, or material suitability for your application, our engineering team is ready to support you.