Imagine assembling a piece of fine furniture only to discover the pre-drilled holes are either too shallow or have poorly formed threads, preventing screws from tightening securely. This frustrating experience is all too common in manufacturing and DIY projects. Thread tapping—the process of creating internal threads—is a critical step that demands precision. With countless tapping tools available, selecting the right one for specific applications can be daunting. This comprehensive guide examines 16 distinct types of taps, detailing their structural features, ideal applications, and selection criteria to help you make informed decisions.

The hand tap is among the most widely used threading tools, suitable for both manual operation and power tools. It performs well in most materials and can handle both blind and through holes. Standard hand tap sets typically include three taps with distinct functions.

• Pros: Highly versatile, broad material compatibility, flexible operation
• Cons: Less efficient with hard materials, prone to wear
• Best for: General-purpose threading in blind/through holes, manual operations

Featuring a 9-thread lead, the taper tap is the first in a hand tap set. Its gradually increasing diameter reduces torque requirements by progressively cutting material, making it ideal for initial threading.

• Pros: Easy start, reduced cutting force
• Cons: Cannot thread blind hole bottoms
• Best for: Starting threads in through holes or preliminary blind hole work

With a 5-thread lead, the plug tap serves as the second tap in a set. It produces more complete threads than taper taps and is used for intermediate threading after initial cuts.

• Pros: Efficient thread formation
• Cons: Limited blind hole bottom reach
• Best for: Intermediate threading in blind/through holes

This tap's minimal 1.5-thread lead allows threading to the very bottom of blind holes. It completes the threading process after taper and plug taps.

• Pros: Full-depth blind hole threading
• Cons: High cutting resistance
• Best for: Final blind hole threading

Designed for pressure-tight pipe connections, pipe taps create precise threads that prevent fluid/gas leakage. They require skilled operation to ensure proper sealing.

• Pros: High-seal threads
• Cons: Demanding operation
• Best for: Hydraulic, gas, and mechanical pipe connections

Its helical flutes efficiently remove chips from blind holes, preventing clogging and improving thread quality, especially in ductile materials.

• Pros: Superior chip removal
• Cons: Less durable in hard materials
• Best for: Blind holes in soft materials

This pipe tap variant meets strict gas/hydraulic system standards for deep threading in tapered/straight holes.

• Pros: Compliant threads for critical systems
• Cons: Limited applications
• Best for: Gas/hydraulic system components

Designed for automated manufacturing, these durable taps handle hard materials and high-volume production, often featuring wear-resistant coatings.

• Pros: High durability, automation-ready
• Cons: Higher cost
• Best for: Production lines, hard materials

Instead of cutting, forming taps cold-work metal into threads through plastic deformation, producing stronger threads without chips.

• Pros: No chips, stronger threads
• Cons: Material limitations
• Best for: Ductile materials like aluminum/copper

With more cutting edges (7-10 vs. standard 3-7), master taps produce exceptionally precise threads in hard materials.

• Pros: Superior thread quality
• Cons: Premium pricing
• Best for: High-precision hard material threading

Combining drilling and tapping in one operation, these time-saving tools feature spiral flutes for various materials.

• Pros: Process consolidation
• Cons: Depth/material limitations
• Best for: High-volume shallow hole threading

These ultra-hard taps tackle challenging materials like sintered metals and carbides, though they're cost-prohibitive for common materials.

• Pros: Exceptional wear resistance
• Cons: Very expensive
• Best for: Aerospace/mold making applications

Extended shanks allow threading in deep or hard-to-access locations, though their flexibility requires careful operation.

• Pros: Deep hole access
• Cons: Reduced rigidity
• Best for: Deep/recessed holes

Optimized for rapid threading in hard materials with minimal power consumption, these feature shallow flutes for efficient material removal.

• Pros: High-speed operation
• Cons: Higher cost
• Best for: Production environments

These 15-20 inch specialty taps were historically used for steam locomotive firebox maintenance, creating threads for mechanical fasteners.

• Pros: Precise stay bolt threads
• Cons: Niche applications
• Best for: Historical equipment restoration

By omitting alternate threads, these taps improve chip clearance and lubrication in materials prone to long chip formation.

• Pros: Enhanced chip control
• Cons: Slightly reduced precision
• Best for: Aluminum/copper threading

• Workpiece Material: Match tap hardness to material properties
• Tap Material: Select appropriate tool steel or carbide
• Hole Type: Consider blind vs. through hole requirements
• Cutting Speed: Align with tap's operational parameters

Mastering thread tapping requires understanding these diverse tools and their specialized applications. By carefully considering material properties, hole configurations, and production requirements, manufacturers and craftsmen can achieve precise, reliable threads for any application.