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One thing to really keep in mind is that form tapping requires a larger drill than a typical drill size for a cut tap.  This larger hole is generated to allow room for the material to flow to create the minor diameter of the thread.

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Our preferred supplier partners that offer a comprehensive range of Form taps include Balax, Dormer, Emuge, North American Tool & Sandvik Coromant.

Form tapping, also known as Roll Form tapping, is typically used in applications where traditional cut tapping is unsuitable. Roll form tapping has several benefits over cut tapping such as faster cutting speeds, stronger threads, no chips generated, stronger tap and longer tool life.

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As a rule of thumb, if a continuous chip is created when drilling, then the material is likely malleable enough and a good candidate for form tapping the threads. However, suitable materials react to form tapping in different ways.

Form tapping is typically used in steels, stainless steels, light metal alloys and non-ferrous materials. Tapping via form tapping is appropriate for materials with tensile strength less than 1,200 N/mm2 and fracture strain of 5 percent or less.

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Cold forming technology has been used to produce threads for more than 100 years. Tap designs have changed considerably in that time. This, combined with the newest coatings, guarantees a very long tool life in most applications.