[AMCTony]

What design considerations need to be addressed when making a custom fastener from bar stock versus a the standard cold heading process. I need to make a small quantity of some bolts for a custom application and I am wondering what material would be best suited for this. I need to have a tensile strength in the aera of a grade 8 fastener and would prefer to use a stainless such as 17-4 H1150. I am assuming that the strength of the bolt using a machining process to manufacture it would be less than a bolt made by cold heading.

[USMCPOP]

Without heat treating or roll forming threads, you will be hard pressed to get the required strength. I don't know much, but that much I do know. Not sure if stainless can even come close...

You might try asking over at www.practicalmachinist.com