When to use a flowtap vs. standard tapping: stronger threads, no chips

Cold forming tapping (Flowtap) vs. cut tapping:

What’s the difference, and when does it matter?

If you’re designing threaded holes in thin-walled metal parts, choosing the right tapping method is essential.

A cold forming tap (also known as a roll tap or Flowtap) works very differently from a traditional cut tap. And in most cases, that difference matters more than you’d think.

What is cold forming tapping?

Cold forming taps create internal threads by plastically deforming the material rather than cutting it.

This process is completely chipless: there’s no material removal, no swarf, and no risk of broken chips stuck in blind holes.

The result is a work-hardened thread profile with excellent dimensional stability.

Flowtaps are well-suited for use after friction drilling, where the collar and sleeve provide extra wall thickness for thread engagement.

How does a cut tap work?

Cut taps (also known as cutting taps or thread cutting taps) use sharp flutes to remove material and form the thread.

While this method is versatile and works in many materials, it creates chips that must be evacuated, and it disrupts the grain structure of the metal, potentially weakening the thread.

In thin-walled applications, cut taps often create weaker threads and can jam due to chip buildup.

When to use a flowtap

Flowtaps are the preferred choice in applications where:

• Friction drilling is used and you want a chipless, clean process
• Thin-walled materials are involved (steel, aluminum, stainless steel, etc.)
• Thread strength and durability are critical
• Automated tapping is required—no chip jams, less tool wear
• Clean manufacturing environments are preferred (e.g. EV battery enclosures, electronics housings)

When a cut tap might still be used?

There are still scenarios where cut taps make sense:

• In brittle materials like cast iron that cannot be plastically deformed
• When deep thread engagement is required in thick sections
• If cold forming taps are unavailable in certain thread geometries
• However, these cases are the exception, not the rule.