US Leading Furniture Supplier × Honscn: Overcoming Custom 8.8-Grade Security Screw Challenges for High-Strength Lock Assemblies

The Product: A Custom Security Screw for High-Stakes Lock Assemblies

This wasn’t your average hardware store screw. Let’s break down what made it unique:

Key Product Details

• Name: Torx Pin Security Screw (the "pin" in the center of the Torx head prevents tampering—perfect for locked furniture)

• Material: 8.8-Grade Iron (tensile strength of 800MPa—tough enough to resist forced entry attempts) + Blue Zinc Plating (for rust resistance, since furniture might live in humid spaces like basements)

• Specs: 3/4"-10 UNC-2A thread (a coarse, heavy-duty thread for strong holding), total length 55.1mm (2.171 inches)—bigger than most standard furniture screws

• Use Case: Holding together high-strength locks on commercial storage cabinets (think schools, offices, or hotels where security matters)

• Process: Cold heading (to shape the screw head and shank) + thread rolling (to create the UNC thread)

The Challenges: Non-Standard Design Broke Molds (and Slowdowns Followed)

This project had two big roadblocks right out of the gate—ones that tripped up the client’s previous manufacturers:

Mold Failure: Too Big, Too Hard

First, this was a non-standard custom screw—no off-the-shelf molds would work. We had to build a 专用 mold from scratch. But when we ran the first test batches:

• The 8.8-grade iron was harder than expected, so the mold kept cracking under pressure

• Even when the mold held, the screw itself would split at the head-shank junction (a weak spot in cold heading for thick, hard materials)

• We wasted 3 batches of material and had to pause production to fix this—frustrating, but we knew rushing would only make it worse

Thread Rolling Nightmares: Slow, Expensive, and Unreliable

The 3/4"-10 UNC-2A thread was the second headache. It’s a large, coarse thread, and 8.8-grade iron doesn’t give easily. Our initial setup with standard thread rolling machines:

• Broke two machine dies in the first week (repairs cost $1,200 each)

• Only made 50 screws a day—way too slow to hit the client’s 30,000-unit order in time

• The threads were inconsistent: some were too loose, some had burrs that would scratch the lock components

• We were burning through labor hours fixing mistakes, and the client was getting nervous about their cabinet production timeline

Our Solutions: Mold Tweaks and Imported Gear to Turn Things Around

We didn’t just "fix" the problems—we rebuilt the process to avoid them entirely. Here’s how:

Mold Optimization: 3 Tries to Get It Right

We knew the mold was the foundation, so we focused here first:

• First tweak: We increased the mold’s hardness from HRC 58 to HRC 62—but it still cracked. Turns out, harder isn’t always better; the mold needed some flexibility too.

• Second tweak: We switched to a different mold steel (local vs. imported) but saw the same splitting issue.

• Third tweak: We used imported Swedish mold steel (STAVAX ESR)—it’s tougher than local steel but has just enough ductility to handle the 8.8-grade iron. We also adjusted the cold heading pressure (lowered it by 15% and slowed the cycle time by 2 seconds) to let the metal flow without cracking.

• Finally—success! The third mold made clean, unbroken screws every time.

Thread Rolling Upgrade: Imported Machine = Speed + Precision

For the thread problem, we decided standard equipment wouldn’t cut it. We invested in an imported Japanese thread rolling machine (built for heavy-duty metals like 8.8-grade iron):

• The machine’s dies were designed for large UNC threads—they didn’t break, even after 10,000 screws

• Production jumped from 50 screws/day to 1,500 screws/day (30x faster!)

• We added a laser thread checker to the line—every screw gets scanned for size and smoothness before moving to plating

• The client was relieved when we shared the first batch of perfect threads—they could finally see the light at the end of the tunnel

How We Manufactured the Screws: Step-by-Step Precision

Once we had the right tools, we locked in a smooth production flow:

• Cold Heading: We fed 8.8-grade iron wire into the optimized mold, shaping the Torx pin head and shank in one press (no secondary cutting needed—faster and more consistent).

• Thread Rolling: The imported machine rolled the 3/4"-10 UNC-2A thread into the shank (thread rolling is better than cutting here—it strengthens the thread by compressing the metal).

• Plating: We dipped the screws in a blue zinc bath, then baked them at 180°C to set the finish—no uneven spots, just a uniform, rust-resistant coat.

• Quality Check: Every 100 screws, we tested:

• • Dimension accuracy (used calipers to check length and thread size—hit ±0.02mm every time)

• • Strength (torque tests to make sure the head didn’t strip—held up to 80 N·m, well above the client’s 65 N·m requirement)

• • Finish (visual inspection for scratches or plating gaps—rejected less than 0.5% of the batch)

Results: 30,000 Screws Delivered—And a Client Who Keeps Coming Back

After two months of fine-tuning and production, we shipped all 30,000 screws 3 days early (the client used the extra time to speed up their cabinet assembly—win-win).

Their feedback said it all:

“Dimensions are spot-on, quality exceeds our expectations, delivery was fast, and the service was professional. We’d tried two other shops before Honscn, and none came close to this level of consistency. We’re already sending over drawings for our next screw order.”—Mike Carter, Client’s Supply Chain Manager

Since then, they’ve placed two more orders (50,000 screws total) and even referred us to another furniture brand in their network.

Why This Matters for Custom Screw Manufacturing

This project isn’t just about a screw—it’s about solving the “too hard” problems other shops avoid. For brands that need non-standard, high-strength fasteners (like furniture with security features, industrial equipment, or outdoor gear), you need a partner who:

• Doesn’t quit after the first mold crack

• Invests in the right tools (not just Band-Aids)
• Keeps you in the loop when things get tough

If you’re stuck with a custom fastener that other manufacturers can’t handle—we’re here to help. Let’s turn your “impossible” screw into a done deal.