Inability to fully extrude parts or excessive pressure to extrude, form heads or control lengths. If there is either a poor finish or pocket in the die, the header operator will need to put excessive pressure on the blank. This pressure will be needed to get the full extrusion, fill the wafer or face shape, or attain the needed blank length. This is unnecessary with a well constructed die. This undue pressure causes premature failure of the die and head forming tooling.

Bent blanks resulting in poor thread rolling and rejection by the end user. This hard to detect symptom of poor I.D. qualities results in many unseen problems demonstrated in the finishing process and end usage of the screw. The detection of the root cause of a problem in the blank at this point is difficult and very costly.