A Stud That Stands Up to Winter
When a leading snow and ice control equipment company faced recurring stud failures in their plow assemblies, they turned to The Federal Group for a custom solution. Drawing on our expertise in custom fastener manufacturing and cold forming, we helped transform a simple stud into a high-performance component built to withstand brutal winter conditions.
The Breaking Point
The clients’s original plow studs were loosening or snapping under constant vibration and heavy impact. Standard replacements lacked the structural integrity to endure freezing temperatures and repetitive stress. These failures led to costly downtime, field repairs, and upset customers — a critical issue during peak plowing season when every minute counts.
A Custom Cold Formed Solution
The Federal Group’s engineering team met with the client and analyzed the root causes of the issues. Using advanced cold-forming services and thread-rolling techniques, we preserved material strength and achieved superior fatigue resistance compared to machined alternatives. Each stud was heat-treated, salt-spray tested, and inspected to ensure consistent performance across large production runs.
The Result: Built to Last
The new plow studs exceeded the client’s performance expectations. Field testing showed a significant reduction in breakage and a measurable increase in service life, cutting replacement frequency and maintenance costs. Through DFM (Design For Manufacturing), The Federal Group helped our client boost reliability, reduce downtime, and maintain operational confidence through the toughest winter conditions.
Your Next Custom Fastener Starts Here
From custom plow studs to structural bolts, The Federal Group delivers specialty fastener solutions that stand up to the elements. Contact our team to discuss your next project or learn more about our custom fastener manufacturing capabilities.