A Orbital Head Forming System is a precision metal forming technology used primarily to deform or shape the heads of cylindrical components—such as tubes, pins, rivets, or fasteners—using a controlled orbital motion. It is commonly found in aerospace, automotive, medical device, and precision manufacturing industries for creating strong, consistent, and repeatable head forms.

Technical Definition:

Orbital head forming is a cold-forming process that uses a conical forming tool (called an orbital head) that presses against a stationary or rotating workpiece at a shallow angle (~3–6°), while moving in an orbital (circular) path. This results in gradual, controlled deformation of the material to form a specific shape, such as a dome, flange, or rivet head.

Key Components of the System:

How It Works (Step-by-Step):

1. The part (e.g., a tube or pin) is loaded into the fixture.
2. The orbital head begins rotating at a shallow angle (typically ~5°).
3. Downward force is applied gradually as the orbital head rolls around the periphery of the part.
4. The head is formed uniformly without excessive impact, heat, or material waste.
5. The final shape (e.g., dome, mushroom, flare) is achieved through controlled plastic deformation.

Typical Forming Applications:

• Rivet and stud head forming
• Sealing and flaring tube ends
• Automotive ball joint or bushing assembly
• Fastening dissimilar materials (metal to plastic)
• Crimping medical devices and connectors

Advantages (Technically):

Typical Industries Using It:

• Aerospace: Rivet forming on aircraft panels or turbine components
• Medical: Precision crimping of surgical tools or catheters
• Automotive: Shock absorber or bearing housing formation
• Electronics: Forming connectors, terminals, battery caps

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