Wire Forming

Wire forming refers to numerous processes that manipulate wire into various shapes, referred to as wire forms. Since there are so many different processes that fall under the header of wire forming, they can be utilized for a vast amount of applications.

One example of an industry that benefits from wire forming processes is the retail and commercial business, which uses wire forming for product placement applications such as customized wire displays, shelving, hooks, baskets, springs, clips, material handling solutions, dividers, and so much more.

Today, a simple technique called wire drawing is still used, among other processes. Wire drawing, a technique like what the Egyptians used to form metal, is still used today and a person can make many sizes and thicknesses of wire using different sets of dies.

The vast amount of company genres that use wire forming include: industrial manufacturing, for storage systems and hardware such as springs and clips; automotive and aerospace, for interior mechanical assemblies such as rings, pins and hooks. The medical industry relies on wire-formed products including medical staples, titanium clips, surgical staples, ligating clips, skin staples and titanium bone staples. Other wire-formed medical parts include medical implants such as guidewires, wire-stents and occlusion devices.

Additional wire formed products include baskets, filters, screens, guards, grids, coils and many more. Wire forming can be performed using both ferrous and nonferrous metals including copper, aluminum, stainless steel, brass, steel and various metal alloys.

Although it is not as common, plastic materials may also be used in wire forming. In addition to wire forming processes, secondary services such as plastic coating, nickel plating, heat treating, painting, anodizing and powder coating can be performed in order to enhance certain physical properties of the wire forms, such as aesthetics and corrosion resistance.

Normally done in diameters of approximately .010 to .750 inches, almost any wire you can think of can be formed. Some of the many processes that can be categorized as a wire forming process include: roll forming, coil making, deep drawing, fourslide wire forming, press wire forming, bending, welding and CNC wire forming. Coil making, also referred to as spring making or coil winding, is the process of winding wires around mandrels, which are metal blanks, in order to create coils.

Fourslide wire forming, also referred to as multislide stamping, is a type of metal stamping that uses a press with four horizontal forming slides in order to allow for multiple forming in different directions. Another form of metal stamping, deep drawing enables a deeper depth to the wire form than is possible with other wire forming processes. Deep drawing involves radially drawing metal sheet into the forming die until its depth is greater than its diameter. This process is critical for applications requiring parts with great depth, as no process can produce as significant of depths as deep drawing.

Press wire forming is similar to the metal stamping methods, and can utilize mechanical or pneumatic presses. Roll forming is a major wire forming process, able to create flat, round and shaped wire parts.

Companies across a broad spectrum of industries must rely on their products to not only effectively operate but the ability to have a customized solution is a huge selling factor for these types of products. Enhanced wire forms can be manufactured to handle higher levels of tolerances and often times manufacturers will maintain a very versatile facility to accommodate a wide array of customer requests since wire forming can create a multitude of products.

CNC wire forming processes utilize computer controls in order to ensure a higher level of precision than with other processes; thus, CNC wire forming can include other wire forming processes such as bending, twisting, turning, and welding but are altered due to the addition of CNC capabilities.

Welding is a fabrication process that joins metals through heat or pressure-induced fusion. Manufacturers may make use of multiple welding types, including TIG welding, MIG welding, laser welding and plasma welding. TIG welding produces the most accurately welded wire, but it takes longer and requires a highly skilled worker to navigate its complexities, so it is often substituted with the simpler MIG welding.

Much like wire welding, wire bending can also be accomplished using a variety of machines and techniques.

Since wire-formed products are nearly everywhere you look, it is time to recognize the significance of these great products. Imagine not having clothes hangers, hooks to hang things on, refrigerator shelving, baskets, or shopping carts, life would not be nearly as easy as it is now.

Plenty of machines in the industrial arena could not function without wire forms such as springs, hooks, coils, pins, rings and clips.Customers must specify what their wire size is, along with the shape and strength desired.

Wire Forming Informational Video