Enhanced devices, systems, and methods for manufacturing undercut threadforms on fasteners

A method of manufacturing a fastener comprising:

• forming at least two opposing undercut surfaces of at least one helical thread disposed about a shaft of the fastener via a cutting process by:
• placing a cutting head of a mill tool at a first position along the shaft;
• rotating the shaft about a longitudinal axis of the shaft;
• and
• translating the cutting head along at least a portion of a length of the shaft to form the at least two opposing undercut surfaces on the at least one helical thread.

A method of manufacturing a fastener comprising:

• forming opposing undercut surfaces of a helical thread disposed about a shaft of the fastener via a first cutting process, a second cutting process, and a third cutting process,
• wherein:
• the first cutting process comprises:
• placing a first cutting head of a first mill tool at a first position along the shaft;
• rotating the shaft in a first rotational direction about a longitudinal axis of the shaft;
• and
• translating the first cutting head along at least a first portion of a length of the shaft to form a fourth open surface and a fifth open surface of the helical thread;
• the second cutting process comprises:
• placing a second cutting head of a second mill tool at a second position along the shaft;
• rotating the shaft in the first rotational direction about the longitudinal axis of the shaft;
• and
• translating the second cutting head along at least a second portion of the length of the shaft to form a first undercut surface and a second undercut surface of the helical thread;
• and
• the third cutting process comprises:
• placing a third cutting head of a third mill tool at a third position along the shaft;
• rotating the shaft in the first rotational direction about the longitudinal axis of the shaft;
• and
• translating the third cutting head along at least a third portion of the length of the shaft to form a third undercut surface of the helical thread.