A strong hex can be attained by cutting the hex hole with endmills. Look at a Snap-On wrench or socket to see that the corners/points aren't just the juncture of 2 flats, but instead, there is a radius formed outside the dimension of the hex.
They claim that this feature makes more efficient use of the torque applied to the tool, and that tools that use the corners/points of the hex actually result in more frequent rounding of the fastener (or breakage of cheaply-made tools).
A mill with a dro or a rotary table would be a fairly quick way to cut accurate hex openings.
WB .............
Does anyone here do this or can fill me in on the process?
All I think I know is that it would be punched out when the piece is red hot and then the wrench would be finished and then heat treated. But I know nothing of how the punching part of the process is accomplished.
Thanks Bob AZ