zlacker

>>gnabgi+(OP)
I'd be interested to know how BMW manufactures those screws. The patterns in the metal in the image suggest the entire hole was drilled out? The deepest part has circular marks inside that looks like the marks left by a facing tool on a lathe or similar. Then I guess the two wedges were inserted and the whole screw faced?

>>voidUp+Zj
I don't see any geometry that would be hard for casting or milling, it's slightly more expensive because you can't do it in one go, but you have to lift the toolhead if you mill.

>>torgin+oM
Screws aren't cast. And lifting the toolhead takes about .1 second.

What's expensive here is milling this screw head at all, and in particular the surface finish.

This is probably just a prototype for shows, though. At scale, screws heads are usually cold-formed, and this design would work for that, too. If you circular brush the head in the end, you'd get pretty close to this, even if you wouldn't get the finish in the pockets. But that doesn't make much sense there anyway, it'd get damaged by the fastening tool.