May. 19, 2025
Metal spinning, also known as spin forming, is a specialized metalworking technique that molds a flat, circular blank or disc into symmetrical round formations. This transformation is achieved through the application of a roller that exerts lateral force against the disc's surface while it spins at high speed on its axis, supported by a mandrel. The mandrel not only stabilizes the workpiece but also determines its final configuration.
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Through metal spinning, a sheet of circular metal is contorted into diverse shapes without any material being removed. During this reshaping, tensile and compressive forces are applied to the disc blank over a mandrel. Certain spinning techniques may result in the thinning of the original metal sheet, but such variations are managed with precision to satisfy specific end-product criteria.
Metal spinning is one of humanity's most ancient metalworking techniques, skillfully merging artistic expression and technical knowledge with a lineage extending back to Egyptian times. Through the ages, it has transitioned from a purely manual endeavor to a refined industrial method that includes computer numeric control (CNC) technology.
Even with technological advancements, traditional manual metal spinning remains crucial for crafting products of precise detail and exceptional quality. Gaining proficiency in this method requires significant apprenticeship and distinctive expertise, underscoring the craftsmanship involved.
As a historical reshaping practice, metal spinning’s origins can be traced to ancient Egyptian pottery forming, originally employing a hand-driven potter’s wheel since BC. While initially used for wood and clay, the technique was adapted by 25 BC for crafting circular iron shields.
During the medieval era, metal spinning became prevalent for making items such as vases, tea kettles, and trophies. These objects were created using a wooden spinning lathe with manual rotational input by an assistant, highlighting the enduring significance and adaptability of this ancient technique across different periods.
Metal spinning machinery, often referred to as spinning lathes or flow forming machines, is a type of precision metalworking equipment designed to form and shape metal blanks into round and hollow cylindrical parts, cones, and complex contours. Used in a variety of industries—including aerospace, automotive, lighting, and industrial manufacturing—these machines utilize a rotating lathe and a hardened roller to apply localized pressure, shaping metals such as aluminum, stainless steel, copper, brass, and titanium with accuracy and efficiency.
A typical metal spinning operation employs advanced technology to deliver high repeatability and surface quality, while still retaining flexibility for custom metal forming. The lathe is the primary machinery in this process, mounting and rapidly spinning the workpiece around its axis. Aside from spinning applications, this versatile equipment is also capable of other metalworking functions, such as precision cutting, CNC drilling, and abrasive sanding. For metal spinning specifically, a custom mandrel forms the inner profile, while the coordinated movement of other components results in intricate spun shapes and precise tolerances. Major components of a metal spinning lathe include:
The mandrel, functioning as a form die or spinning mold, determines the geometry of the final spun metal part. As a critical tool in metal shaping, it provides full support and accurate profile definition, ensuring the metal disc conforms tightly during the entire spinning process. Mandrels are specially designed to minimize workpiece wrinkling and deformation, making them essential for achieving precision-engineered results.
Prior to mounting, the metal blank—often pre-lubricated with high-performance grease or wax—is carefully positioned on the mandrel. This lubrication is key for reducing friction during high-speed rotation, improving both material flow and the visual surface finish of the finished component.
Mandrel construction materials are selected based on application requirements. Industry standards favor hardened steel or aircraft-grade aluminum for high-volume production and tooling longevity. For prototypes or low-run jobs, cost-effective mandrels made from engineering plastics or hardwoods can be suitable. Regardless of material, durability and structural integrity are vital, as mandrels must resist deformation under strong radial pressure from the roller tool.
The roller, also referred to as a spinning tool or forming roller, is meticulously engineered to apply sequential, localized force to the workpiece over the mandrel’s contour, creating controlled plastic deformation. Modern rollers often feature ball bearings for smoother operation, reduced heat, and minimized tool wear—critical factors when working with harder metals such as stainless steel or Inconel alloys.
Roller adjustments are finely tuned to balance pressure and speed, essential for producing uniform wall thickness and intricate metal contours. Although manual operation by a skilled technician enables creative custom forming, the increasing prevalence of CNC-controlled metal spinning machines allows for highly repeatable, near-flawless results in both prototype and mass production environments.
CNC and advanced automation in metal spinning have opened new possibilities for complex geometries, reduced labor costs, and efficient material utilization. This technology is favored for manufacturing components like satellite dishes, pressure vessels, cookware, lighting fixtures, and automotive wheels—all requiring impeccable surface finishes and structural strength.
A distinct advantage of metal spinning is that relatively lower forming force is needed compared to traditional stamping or deep drawing. This allows effective forming of heavy-gauge, high-tensile metals into large diameters without the excessive energy demand found in press forming. As a result, the process is both cost- and energy-efficient.
The work zone in metal spinning features synchronized movement—combining part rotation and roller advance—to create a signature spiral or helical flow. This generates seamless and high-strength spun parts, with a slight twist or spiral that also enhances structural integrity.
The tailstock assembly, installed opposite the headstock, maintains axial alignment and provides robust support for the workpiece against the mandrel during rapid spinning or flow forming. Precision adjustment mechanisms enable consistent pressure to clamp the part securely, a crucial element for accuracy during high-speed or heavy-gauge metal spinning.
The follower, or pressure pad, is a tailor-made component attached to the tailstock spindle. Designed to match the base of each spun part, it evenly distributes holding force, preventing slip and ensuring that the metal blank conforms precisely to the mandrel during rotation. High-quality followers contribute to surface finish consistency and repeatability—critical for demanding industrial applications.
The main drive spindle in the headstock serves as the axis for both the mandrel and workpiece, delivering rotational energy throughout the forming process. Tailstock assemblies often feature a synchronized spindle that holds the follower, ensuring full axial support and precise movement control. Direct-drive and belt-drive spindles are chosen based on application speed and torque requirements.
The headstock is a heavy-duty structural housing that contains the powertrain, including motors and gears for variable speed control, high-torque operation, and precision spindle alignment. It supports and stabilizes the entire assembly during high-speed rotation—key for safety and dimensional accuracy in both manual and CNC spinning operations.
Serving as the engineering foundation for all primary components, the lathe bed is manufactured for rigidity and vibration damping. It ensures that the headstock, tailstock, and tool rests remain in perfect alignment while withstanding high operational loads. An accurately machined and robust bed boosts both process consistency and equipment longevity.
CNC metal spinning is a state-of-the-art evolution in metal fabrication. By integrating computer-aided design (CAD) and automated control systems, CNC metal spinning lathes offer exceptional precision, replicability, and process monitoring for both thin and thick metal sheets. The operator loads a blank on the CNC lathe and secures it using a hydraulic or mechanical pressure pad, programmed with detailed geometries and production sequences.
Upon activation, the CNC spinning machine executes the programmed tool paths, controlling spindle speed, roller pressure, and feed rates to manufacture intricate contours and high-precision components. CNC-controlled lathes are renowned for producing parts with minimal setup time, superior dimensional consistency—often within 0.001 inches (0.01 mm)—and outstanding mechanical properties such as improved tensile strength and fine-grained surface finishes.
Embraced by industries demanding low- to high-volume production, CNC metal spinning is a go-to solution for aerospace components, lighting reflectors, gas cylinders, and custom-engineered industrial products. Automation reduces operator error, cuts production costs, and delivers the flexibility to quickly switch between product runs, meeting the strict demands of today’s manufacturing marketplace.
Playback Numerical Control (PNC) metal spinning bridges manual craftsmanship and automated production. In this process, a skilled operator uses a joystick or pendant to manually control the roller during the first production run, shaping the metal into the desired geometry under real-time observation. Every movement is recorded by the system's control software.
After the initial part is successfully formed, the PNC system stores and plays back the recorded motions, allowing for rapid and repeatable production of complex parts. Program refinement—such as optimizing roller feed rates, correcting geometry deviations, or integrating enhanced safety protocols—ensures production accuracy and reduces scrap rates.
PNC metal spinning is especially valued for high-volume production environments where consistency, quick changeover, and process reliability are paramount. Applications include serial manufacturing of commercial lighting components, HVAC ducting, and pressure vessel ends, where the demand for precision and consistent quality is essential.
Today's metal spinning machines deliver several competitive advantages versus traditional forming methods. Metal spinning supports rapid prototyping, lean manufacturing, and just-in-time production, making it a preferred technique for custom and contract manufacturers. The process reduces material waste, lowers tooling costs, and allows for complex shapes that might be challenging or cost-prohibitive with deep drawing or stamping. High-precision spun parts offer superior strength-to-weight ratios, tight tolerances, and smooth finishes—attributes essential for advanced engineering and demanding industrial standards.
Choosing between manual, CNC, or PNC metal spinning machines depends on your production needs, material type, part geometry, and volume requirements. When evaluating machinery, consider spindle power, lathe bed rigidity, maximum blank size, available controls, tooling compatibility, automated material handling, and after-sales support. Partnering with a reputable metal spinning equipment manufacturer or service provider ensures optimal machine performance, long-term durability, and high-quality spun metal components tailored to your application.
Besides core metal spinning processes, specialized services such as custom metal spinning, CNC prototyping, post-spinning heat treatment, and advanced surface finishing greatly extend the capabilities of metal spinning shops. The process serves diverse markets, including defense, consumer products, energy, architectural lighting, and experimental design. For a deeper dive into customized spun parts or requesting quotes, explore our metal spinning services or connect with experienced metal spinning manufacturers through our trusted directory.
In the United States and Canada, there is a wide range of machines available for metal spinning. These machines play a crucial role in modern industry by facilitating the cost-effective and efficient production of metal components used across various sectors, including aerospace, automotive, electronics, and more. They contribute significantly to technological progress and economic development. Below, we explore several leading machines and their features.
The Leifeld PNC350-800 is a well-regarded CNC metal spinning machine recognized for its advanced automation, precision, and reliability. It is designed to accommodate large workpieces, making it ideal for manufacturing metal components for industries such as aerospace and automotive. The CNC control system enables programmable setups, enhancing both efficiency and versatility.
The MJC Engineering E-400 is a popular option for metal spinning, known for its user-friendly interface and CNC control that simplify programming and operation. Its robust construction and powerful performance allow it to tackle heavy-duty spinning tasks with exceptional accuracy and repeatability.
The Baileigh R-M10 is a manually operated metal spinning machine, perfect for smaller workshops and hobbyists. Although it lacks the automation of CNC models, it is favored for its affordability, compact design, and ease of use. It is well-suited for small-scale projects and prototype development.
The PNC-CNC series includes a range of models equipped with CNC controls to meet diverse metal spinning requirements. Renowned for their durable construction, intuitive interfaces, and outstanding performance, these machines are engineered to excel in both precision and productivity for metal forming tasks.
The LNSpin LS-250 is a highly versatile automatic metal spinning machine, ideal for high-volume production. It features automatic loading and unloading, which minimizes manual handling and boosts efficiency. Known for its reliability and quick cycle times, the LS-250 is a favored choice among manufacturers.
Keep in mind that the availability and popularity of specific models may have changed since this update. When selecting metal spinning machines, it's crucial to review current offerings from manufacturers and evaluate factors such as features, production capacity, automation, and budget to find the best option for your needs.
Spinning is categorized as compressive draw forming due to the radial, tensile, and compressive stresses that affect the metal flow within the localized roller work zone and nearby regions. Tensile stresses arise when the roller makes contact with the workpiece, increasing with the axial feed of the roller, which causes volumetric displacement in a plane radial to the mandrel.
As the metal volume decreases towards the center, compressive stresses form between the metal volumes. These stresses contribute to increased thickness at the open end and may lead to buckling and wrinkling. Adjustments in the direction of the feed can help mitigate these issues.
In conventional spinning, the roller directs the workpiece over the mandrel's contour, maintaining a constant material thickness throughout the process. After shaping, the workpiece's depth increases while its diameter decreases. This method is regarded as the most basic form of metal spinning and involves less complex tooling and machinery.
In shear spinning, the rollers apply a downward force as the workpiece is shaped over the mandrel's contour. This process results in a final part with a reduced material thickness compared to the original blank, while maintaining a constant diameter. The depth of the workpiece increases, and the increased compressive forces enhance the part's mechanical properties, such as strength and hardness.
Shear spinning demands a more robust tooling design and precise machining to ensure dimensional accuracy and a good surface finish. The process creates significant friction and wear on both the workpiece and mandrel, necessitating the use of coolant to manage the heat generated.
The thickness of the final material in a shear spinning process is theoretically governed by the Sine Law. According to this law, the final thickness of the part is calculated by multiplying the original thickness of the flat metal sheet by the sine of the semi-apex angle of the cone. This principle is applicable when the part has a conical profile achieved through a single-pass shear spinning process. The metal that remains perpendicular to the spinning axis will retain its initial thickness.
Hot spinning involves heating the workpiece to forging temperatures using a heating torch, which is applied while the workpiece is pressed over the mandrel. This technique is employed when the material exhibits low ductility and malleability or if the metal sheet is excessively thick and hard to deform at room temperature. Cold spinning, performed at ambient temperatures, is suitable for a wide range of metals.
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Suggested reading:During hot spinning, the metal is deformed in its plastic state, which allows for substantial deformation and refinement of the grain structure, enhancing physical properties such as strength. However, the process leads to rapid oxidation of the heated metal, making it harder to control and more costly overall.
Tube spinning is a variant of shear spinning designed to elongate and reduce the wall thickness of hollow cylindrical tubes. The process begins with the tube being mounted and secured on the mandrel. The elongation is achieved by drawing the tube over the mandrel's length using three or more rollers positioned equidistantly around the tube. The axial flow of the material follows the direction of the roller movement.
Tube spinning can be carried out externally or internally relative to the mandrel. In external tube spinning, the tube is stretched over the mandrel's outer surface. Conversely, in internal tube spinning, the tube is spun and elongated inside a hollow mandrel.
This method is effective for creating tubes with varying diameters, provided that wall thickness is not a critical factor. Similar to shear spinning, tube spinning demands a complex tooling design and enhances the mechanical properties of the tube.
To achieve the desired thickness and finish of the workpiece, adjustments can be made to various parameters, including RPM, roller shape and diameter, pressure, attack angle, and feed rates. In some cases, a second pass may be required to reduce the outside diameter near the edge of the workpiece.
Adjusting the edge of the workpiece can be challenging, as it may result in edges that need trimming or become excessively sharp. Careful adjustments are necessary, as each pass of the roller can make the material increasingly brittle and prone to spring back from the tool.
Necking and expanding are additional techniques used in metal spinning. Necking involves the gradual reduction of the diameter in a specific section of the part, while expanding refers to the increase in diameter in a particular section.
After metal spinning, two common post-processes are planishing and trimming. Planishing is used to smooth out wrinkles and marks left by the tool on the finished part. This step involves using a planishing tool to apply force while the workpiece is spun at a slower RPM. Trimming involves cutting away any excess material from the edges of the finished part to achieve the desired shape and dimensions.
Metal spinning is versatile and can be used with various types of metals. If a metal can be processed by metal stamping, it can also be spun. Additionally, some metals that are challenging to form through stamping can be successfully shaped by spinning. However, metal spinning lathes typically operate at pressures up to 15,000 psi, which limits their ability to deform metals such as carbon steel and tool steel.
Aluminum is a favored material for metal spinning due to its excellent strength-to-weight ratio, ductility, and malleability. These properties make it a preferred choice in the metal spinning industry. Aluminum is widely used because of its high resistance to corrosion and chemicals, as well as its thermal stability. It serves as a cost-effective and lightweight alternative to steel.
Commonly used aluminum alloys for metal spinning include , , , , , and .
Spun aluminum parts can be found in a variety of applications, including cooking utensils, kitchenware, drums, funnels, decorative elements, electronic device components, appliances, and furniture.
Steel, an alloy primarily composed of iron and carbon along with other elements, exhibits varying properties based on its specific composition and the manufacturing methods used. These properties influence its workability and performance during metal spinning.
Stainless steel, defined by its chromium content of at least 10.5%, along with additional elements like nickel, molybdenum, and manganese, is renowned for its superior resistance to chemicals and corrosion. It offers exceptional strength, toughness, and rigidity, which are preserved even under high pressures and temperatures.
Carbon steel primarily consists of iron and up to 2% carbon. This composition enhances strength and rigidity but also increases brittleness, reducing malleability and ductility. The higher carbon content diminishes corrosion and chemical resistance, though carbon steel remains a cost-effective choice.
Carbon steel is categorized into low carbon or mild steel (less than 0.3% carbon), medium carbon steel (0.3 - 0.6% carbon), and high carbon steel (more than 0.6% carbon).
The steel's manufacturing process affects its workability in metal spinning. Hot-rolled steel, processed at temperatures exceeding its recrystallization point, is more ductile and malleable but prone to oxidation, which can weaken it. Cold-rolled steel, rolled at room temperature, is less flexible but maintains strength and is also suitable for metal spinning.
Steel, in its various forms, is ideal for heavy-duty applications and is widely used in automotive, construction, manufacturing, and aerospace sectors. It is commonly employed in the fabrication of pressure vessels, tanks, and processing equipment.
Brass is an alloy of copper and zinc known for its excellent thermal and electrical conductivity. Its copper content imparts resistance to corrosion, microbial growth, and biofouling. Brass is also valued for its attractive color, ranging from dull yellow to reddish hues, which makes it ideal for decorative applications.
With its good ductility and malleability, brass is highly workable during metal spinning. Common applications for spun brass parts include musical instruments, pipes and fittings, structural elements, furniture, and various electronic devices.
Bronze is an alloy primarily composed of copper and tin, with additional elements like manganese and phosphorus. It is known for its distinctive yellowish-brown color and offers higher strength and rigidity compared to brass. Although heavier than brass and stainless steel, bronze maintains many of the beneficial properties of copper, including good weldability.
Parts made from spun bronze are highly durable and exhibit superior strength. Common applications include sculptures, musical instruments, trophies, engine components, and structural elements. However, bronze is less malleable and harder than brass.
Hastelloy is a specialized metal alloy composed of nickel, chromium, and molybdenum. Renowned for its superior resistance to chemicals, oxidation, and corrosion, this alloy is frequently employed in demanding environments. It is commonly used for manufacturing tank heads in pressure vessels found in oil refineries, power generation facilities, and chemical plants, as well as in various automotive and aerospace components. With its impressive strength and durability, Hastelloy performs exceptionally well under high temperatures and pressures.
Titanium is a metal known for its excellent strength-to-weight ratio and resistance to chemicals and corrosion. It's both lightweight and flexible, which makes it ideal for metal spinning applications. Despite these advantages, titanium is quite costly and less commonly used for spinning compared to other metals.
Metal spinning is an effective technique for producing concentric and symmetric parts in low to medium production volumes, especially when the expense of metal stamping dies is too high. For larger production runs, metal stamping becomes more cost-efficient and faster compared to metal spinning.
Certain metal shapes are too intricate for metal stamping to handle efficiently and are best created through metal spinning due to their unique design requirements.
Metal hemispheres are versatile components used in a variety of applications, including lighting fixtures, reflectors, mixing bowls, satellite dishes, tank heads, covers, caps, and domes. They can feature either straight or curved walls and are crafted from materials such as cold rolled steel, stainless steel (grades 304 and 316), aluminum, copper, and brass.
Funnel shapes, hopper designs, and cone-shaped pendants.
Venturi tubes used in dust collectors, fans, blowers, and air scrubbers.
Bells, antenna reflectors, satellite dishes, lighting fixtures, and supports for columns and stands.
Tubes, vessel and tank casings, gas containers, and canisters.
Hopper lids and bases are crafted through hand spinning to handle different materials. These components are made from premium aluminum, spun and trimmed to meet specific customer requirements. Occasionally, additional processing is needed, such as incorporating holes and slots.
Metal spinning is a fabrication technique used to manufacture tank heads for pressure vessels, storage tanks, and various process equipment. Given that these vessels often endure high pressures and challenging conditions, the goal is to produce seamless, robust, and resilient tank heads through metal spinning. This process demands meticulous control to meet stringent regulations regarding dimensions, strength, and material composition.
Typical shapes of tank heads include:
The benefits of the metal spinning process include:
The drawbacks and constraints of the metal spinning process are as follows:
Many businesses and consumers are often stunned when asked about Metal Spinning. Regularly we hear “What is Metal Spinning?” “How can Metal Spinning benefit my Business?” This blog post aims to address these questions, the first in brief, the second in a little more detail by highlighting the advantages and then the disadvantages.
Metal Spinning, sometimes called Metal Forming, is a unique process we like to refer to as an ‘art’. It’s been used since the time of Ancient Egypt and has advanced with technology to fulfil the needs and requirements of modern industries of today. The process itself requires a sheet metal disc, rotating at high Rotations per minute (RPM) and is formed over a tool, usually made from a Metal or Wood, to create the desired shape. For a more detailed post on Metal Spinning read The Ultimate Guide to Metal Spinning.
Metal Spinning is widely used in industries from lampshade design displayed in retail outlets to components for military use in the Defence Industry. And there are many advantages when choosing a metal spinner to supply components for your business. There are many advantages your business can benefit from when choosing to use a Metal Spinning company such as ours, to supply components for your supply chain. These include the following;
The Metal spinning process produces less waste and is considered the most conservative metal forming process with materials in comparison to forging, stamping, casting etc. This is because the metal spinning process uses the entire sheet metal disc. The waste product of the metal itself occurs during the cutting stage (to produce the metal disc from sheet metal), Cutting (during the spinning process) and Deburring. The leftover metal scraps, however, are then sent off to be recycled and therefore reused.
If your business values an Economically Efficient supply chain, then you should consider using a Metal Spinning business. Especially as the UN Sustainability Development Goals (SDGs) are now being incorporated into many businesses.
Tooling costs are low, this is because tools can be crafted in relation to the life expectancy of the job function it is designed for. For example, if you were to order a one-off order, we would produce the tool out of wood. For long life orders, the tool would be produced using hardened D2 steel. This is more expensive than a wooden tool, but your business will save more money on tooling costs with a one-off purchase. The alternative would be to purchase numerous wooden tools which would not be cost effective.
We provide tool storage as part of our service for up to one year of the last order. This further saves costs and time when it comes to your next order for long-term orders.
In comparison to conventional casting and stamping, Metal Spinning is much less costly due to the simplicity behind tooling. Furthermore, the fabrication processes within Excell that compliment Metal Spinning further saves costs, providing a complete manufacturing solution to your metal spinning needs.
The company is the world’s best Metal Spinning Materials supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
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