An advanced upsetting process for spherical bone screws was studied, and the difficulty to strip the punch was solved by the unequal diameter die, so the drive groove and the head primary profile of the bone screw were formed. Then, the head contour was amended, and the tail thread was processed by special machine. Finally, the threat forming was conducted. Comparing with the traditional turning process, the material utilization ratio was increased by double, and the production efficiency was increased by two times. Furthermore, the bone screws formed by upsetting for Ti6Al4V ELI and Ti6Al7Nb were tested microstructure, hardness and torsion properties. The microstructure and hardness met the standard requirements. The maximum torque and fracture torsion angle of the developed screws were essentially consistent with those made by turning process. Therefore, the upsetting process can substitute for the traditional turning process.