Capabilities
Every step,
under one roof.
From steel wire rod to a packed, traceable part — drawn, forged, finished and inspected by REL. Four divisions, one chain.
Wire drawing & annealing
Most forging shops buy wire and inherit what they are sent. We buy steel and draw it ourselves.
- Pickling, descaling and phosphate / lime coating before drawing
- Drawn to gauge from Ø2.20 to Ø28 mm, tolerance held batch to batch
- Spheroidise annealing in our own bell furnaces since 2012
- Grades: 1010 · 1018 · 1541 · 10B51 · 15B25 · 15B41 · EN8D · EN18D · 4140 · 16MnCr5
- Size range
- Ø2.20 – Ø28 mm
- Capacity
- 40,000 t / year
- Condition
- Annealed · drawn
- Supply
- Coil or carrier
Cold forging
Three- to seven-station formers build the geometry blow by blow, at room temperature, with almost no scrap.
- Part formers, bolt makers, head forging machines and nut formers
- Load sensors on every die block — the machine stops itself if the force runs high
- Extra-long parts up to 330 mm, including splined and drive shafts
- Forging speeds up to 150 pieces a minute
- Thread size
- M3 – M24
- Length
- up to 330 mm
- Stations
- 3 – 7
- Capacity
- 20,000 t / year
Tool room
Every die is designed and cut in-house. REL machines do not stop for want of a tool.
- AutoCAD 2D, Autodesk 3D and forming simulation on critical parts — targeting 90% accuracy at T0
- EDM, wire-cut, lathes, surface, cylindrical and tool & cutter grinders
- Reverse engineering from a sample; standards library and sample room
- Fast tool maintenance and breakdown support
- Design
- AutoCAD 2D · Autodesk 3D
- Simulation
- Forming simulation
- Manufacture
- 100% in-house
- T0 target
- 90% accuracy
Thread rolling. Two dies press the thread into the forged blank. Cold formed — no chips, unbroken grain flow, a stronger thread.
Drilling. Axial and cross holes on special-purpose machines, after forging.
Slotting. A slitting saw cuts the slot across the head.
Tapping. Nuts are tapped after forming, on automatic tapping machines.
Trimming. The forged round head is pushed through a hex trim die; the flash ring falls away.
Washer assembly. The washer goes on before thread rolling, so it stays captive on the screw.
Patching. A pre-applied nylon patch on the thread resists loosening under vibration.
Representative 3D
Threading & secondary operations
Some features cannot be forged. They are added after forging — and checked 100%.
- Thread rolling for bolts, automatic tapping for nuts — up to 300 pieces a minute
- CNC and Traub turning
- Special-purpose machines: drilling, buffing, vibro finishing, press and robotic stamping
- Washer assembly and pre-applied thread-lock patches
- Threads
- Metric & inch series
- Rolling
- up to 300 pcs / min
- Turning
- CNC · Traub
- SPM
- Drill · buff · vibro · stamp
Plating & coating
Nickel and nickel-chrome in-house; zinc and zinc-flake through approved partner lines.
- In-house nickel and nickel-chrome plating with an effluent treatment plant
- Zinc plating with hydrogen de-embrittlement — dedicated partner line
- Geomet, Magni and manganese phosphate via approved partners
- Double fume extraction; captured fumes are recovered
- In-house
- Ni · Ni-Cr
- Partners
- Zn · Geomet · Magni · MnPh
- Environment
- ETP · fume recovery
- Since
- 2024
100% inspection & sorting
Only defect-free parts leave our factory — every piece is checked, not a sample.
- Multi-camera optical sorting — up to 300 pieces a minute
- 100% go / no-go gauging machines
- Visual and surface inspection under magnification
- MPI on safety-critical items
- Method
- Optical · gauging
- Speed
- up to 300 pcs / min
- Cameras
- up to 12 per machine
- Scope
- Every piece
Packing & logistics
Retail-ready or bulk to your line — barcoded, traceable and container-loaded from our own dock.
- Bulk, pouch (single or multi-piece) and blister packs with barcodes
- Barcodes verified on an RJS Inspector D4000
- Rust-preventive packing available
- SAP-tracked batches and containerised export
- Warehouse
- 2,00,000 sq ft
- Packs
- Bulk · pouch · blister
- Barcode QC
- RJS D4000
- Tracking
- SAP
How a new part reaches you
From enquiry to first shipment.
- 01
RFQ & feasibility
Drawing or sample in. Cold-forgeability, material and tonnage review.
- 02
Tool design & simulation
100% in-house — AutoCAD 2D, Autodesk 3D, forming simulation targeting 90% accuracy at T0.
- 03
Tool manufacture
Cut in our own tool room — EDM, wire-cut, grinding. No outside queue.
- 04
Samples & PPAP
T0 samples, dimensional and metallurgical reports, documentation to IATF 16949.
- 05
Production & dispatch
SAP-tracked batches, 100% inspection, barcoded packing, containerised export.
Next step
Check if your part can be cold forged.
Send a drawing — we review cold-forgeability, material and tonnage.