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The metal clinching process has undergone major innovations in recent years, making it highly suited to assembly workflows even when clinching dissimilar metals, a capability that many manufacturers previously thought was not achievable with clinching. BTM Company, a partner of Hawker Richardson in Australia, has introduced several portable and process-driven advances that expand the possibilities for white goods, garage doors, automotive, and similar sectors.
Modern clinching systems, particularly those developed by BTM, now handle material combinations that were once considered impossible or too challenging. This includes joining aluminium to steel, advanced high-strength steels to high-grade aluminium alloys, and a variety of thickness combinations that would have been rejected in the past.
BTMās advancements in tooling geometry, metallurgical expertise, and processing techniques have fundamentally shifted what can be clinched. Their engineering team reports success with individual layers ranging from 0.3 millimetres up to 7 millimetres, and total stack thicknesses reaching 14 millimetres.
BTM emphasises that these breakthroughs stem from scientific approaches to metallurgical and process challenges that were previously unsolved. Another notable benefit is the ability to join pre-painted or coated metals with clinching without damaging the finish, as the process applies no heat. This protects surface finishes that would otherwise be compromised by welding or other heat-based methods.
For manufacturers dealing with large assemblies, refrigerator frames, garage door panels, or automotive body components, the logistics of moving parts to fixed welding stations have always been a pain point. BTM hand-held presses are available with pneumatic, air-over-oil, hydraulic and battery power with a range of tool sizes and configurations.
BTM originated the sealed clinch joint and is the global leader in developing clinch joining technology, along with premium tooling and manual and automated clinching equipment and presses. Their patented Tog-L-LocĀ® system has become the industry standard across automotive, appliance, HVAC, construction, and garage door industries worldwide.
The portable options are particularly innovative. BTM’s Battery Clinch Unit was specifically designed to enable the Tog-L-Loc joining process to be performed in locations without any access to power sources, providing full mobility and flexibility for users. For HVAC applications, their Crocodile Clinch Unit features a built-in 360-degree rotating handle, allowing operators to transition from horizontal to vertical flanges with a simple twist of the wrist.
BTMās Custom-Loc and Special-Loc tooling families provide tailored solutions for manufacturers facing demanding joint configurations and difficult-to-access locations. These tool sets feature innovative geometries designed to reliably join complex or narrow joints, such as those found on narrow flanges or tight spaces where conventional tooling cannot fit. This flexibility helps manufacturers reduce material usage and weight while meeting precise structural demands.
These specialised tooling families are engineered to handle a broad spectrum of metal alloys and thicknesses, including pre-finished materials with coatings such as galvanisation or paint. This capability ensures that even coated or pre-painted surfaces maintain their finish during clinching, preserving aesthetic and protective qualities. The combination of advanced tooling design and material compatibility broadens the range of applications where clinching can be effectively and efficiently applied.
When compared to spot welding, the total cost of ownership, including machinery price, consumables and maintenance, yields considerable savings, up to 50 per cent in some cases.
The savings come from multiple sources:
No more pre- and post-weld processing. The lack of heat in the clinching process allows options that would be untenable with spot welding or would require considerable post-processing. For pre-painted material, paint needs to be removed before welding, and touched up afterwards.
Reduced skilled labour requirements. The savings magnify when compared to arc welding, where major process improvements can eliminate the need for much more expensive skilled welding processes.
Lower equipment costs. No need for expensive welding fume extraction systems, no consumables like welding wire or shielding gas, and minimal maintenance requirements.
Environmentally friendly. It is an environmentally-friendly process ā no sparks, fumes or heat.
HVAC uses include ductwork, air distribution boxes, louvres, air vents and metal filter frames. Other uses include unautomated manufacturing of appliances, drawer slides, garage doors, metal roofing components and channel lettering. Ā BTM’s portable units excel in assembling refrigerator frames, washing machine cabinets, and dishwasher components, where multiple joint locations make fixed press equipment impractical.
The garage door industry has traditionally relied on spot welding or mechanical fasteners for panel assembly. BTM’s portable clinching machines offer a faster, cleaner alternative that maintains the structural integrity required for repeated cycling operations. Tog-L-Loc delivers strong, highly fatigue-resistant joints, with leakproof performance as an added benefit.
From body panels to structural components, electric vehicle battery enclosures are a growing application, such as hybrid assembly processes that combine adhesive bonding and clinching.
With the correct balance of timing and thickness, the hybrid connection can see significant strength gains of 30 per cent or more versus using either bonding or clinching individually. Clinching can also secure an assembly for movement further down the assembly line, while keeping the adhesive secure enough to cure in the assembly without losing part alignment.
While portable clinching machines solve many problems for large assemblies and multiple joining locations, manufacturers with dedicated workstations can benefit from BTM’s Air Toggle Press systems, available through Hawker Richardson.
The BTM Air Toggle Press uses patented “THIN” air-powered toggle technology to produce high forces using just 80 psi (5.5 bars) air pressure. A unique pivoting, rectangular piston drives a non-rotating ram through a force-multiplying toggle linkage, delivering the power needed for clinching, piercing, riveting, stamping, and bending operations in a fast, low-cost assembly solution.
These benchtop presses are ideal for stationary workstations where operators bring parts to the press rather than moving equipment to the assembly.
If you dismissed clinching five or ten years ago because it “couldn’t handle dissimilar materials,” it’s time for a fresh look. The technology has evolved dramatically, and the economics are compelling:
ā Join dissimilar alloys reliably
ā Handle extreme thickness variations
ā Eliminate welding costs and skilled labour requirements
ā Work with pre-finished and coated materials
ā Portable solutions for large assemblies
ā Benchtop solutions
ā Up to 50% cost reduction vs. welding
For Australian manufacturers, BTM’s innovative metal clinching solutions are available through their partnership with Hawker Richardson. This local connection ensures you have access to:
Our experts work with customers and the BTM team, from concept development to after-sales support, to deliver optimised production equipment.
Contact Hawker Richardson today and schedule a hands-on demonstration of BTM’s portable clinching solutions.Ā Click on the link below and fill out the form.
http://44648610.hs-sites.com/book-a-clinching-demonstration
The following FAQs expand on the metal clinching process and major innovations in recent years.
Metal clinching is a joining process that mechanically interlocks sheet metals without heat or welding. Recent innovations by BTM have made it possible to join dissimilar metals such as aluminium to steel and advanced high-strength alloys, including a broad range of thicknesses, which were previously considered difficult or impossible to clinch.
The metal clinching process applies no heat, unlike welding, so it preserves the surface finish of pre-painted or coated metals. This means the finish is not damaged or compromised, allowing clinching to be used effectively on coated materials like galvanised or painted metals.
BTM offers hand-held clinching presses powered by pneumatic, hydraulic, air-over-oil, or battery units. Their battery-powered clinching units enable fully portable operation without power sources, ideal for large assemblies like refrigerator frames, garage doors, and automotive bodies where moving parts to fixed stations is impractical.
BTMās Custom-Loc and Special-Loc tooling families provide specialized tool geometries for tight spaces, narrow flanges, and complex joints. These tools can clinch various metal alloys and thicknesses reliably, including pre-finished and coated materials, reducing material usage and weight while meeting structural needs.
Clinching can reduce total costs by up to 50% compared to spot welding due to eliminating pre- and post-weld processing, lowering skilled labour needs, reducing equipment costs (no welding consumables or extraction systems), and being environmentally friendly with no heat, sparks or fumes.
Metal clinching is widely used in white goods manufacturing (e.g., refrigerator frames, washing machine cabinets), HVAC (ductwork, vents), garage doors, and automotive sectors (body panels, battery enclosures). These applications demand strong, fatigue-resistant joints with minimal surface damage and high structural integrity.
Weber, A. (2025, July 1). “What’s New With Clinching.” Assembly Magazine.
https://www.assemblymag.com/articles/99365-whats-new-with-clinching
BTM Company – Ā https://btmcomp.com/clinching-equipment
