Custom Wire Forming Company
As a wire forming manufacturer, The Federal Group makes components with wire forming techniques, including secondary operations like threading and coating. To meet the diverse needs of our clients, our capabilities include custom wire shaping, CNC wire bending, and assembly services.
Request a QuoteAdvanced Technologies
Automated 3D wire benders, dual feed systems, and CNC forming
Quality Inspections
PPAP submissions and material testing per ASTM standards
Custom Shapes
Four-slide machines and multi axis benders for complex applications
Diverse Materials
Specializing in aluminum, brass, copper, stainless steel, and more
Wire Forming Case Study
See how TFG leveraged custom wire forming and secondary operations, including powder coating, to manufacture a durable, safety-critical blade guard for an industrial fan. Explore the full wire forming case study to learn how integrated manufacturing processes delivered long-term performance and brand consistency.
Industries We Serve
The Federal Group’s custom wire forming services are trusted by a wide range of industries. From the medical field and electronics sector to industrial, manufacturing, and construction industries, we specialize in delivering custom solutions for businesses. Through leveraging advanced technologies, we provide quality wire forming solutions to deliver high performance parts at cost-effective prices.
Medical Devices and Healthcare
In the medical and healthcare industry, devices and equipment must comply with strict standards and regulations. With advanced wire forming technologies, The Federal Group delivers custom solutions with exceptional precision. As a trusted medical equipment manufacturer, we use high-quality materials and specialized coatings to meet industry standards in everything from common applications like wire shelving to complex shapes such as surgical instruments.
Electronics and Industrial Engineering
Wire forming is used in the electronics and industrial engineering sectors to create a variety of components, from wire racks and enclosures to battery contacts and lightbulb filaments. We provide decades of experience manufacturing components for these industries, capitalizing on efficient wire forming processes to save our clients time and money.
Construction
Wire forming plays a vital role in the construction industry by providing durable components like custom brackets and fasteners. Wire forming is also used to manufacture protective barriers, wire mesh, and chain link fencing, all of which are essential to safe construction practices. By crafting components from high quality steel and other special alloys, TFG USA ensures that the construction industry meets regulatory requirements and provides for safety and reliability in every application.
Customized Wire Forming Manufacturing Technology
TFG utilizes advanced, automated wire forming technologies to produce complex wire forms with high accuracy, repeatability, and efficiency. Our equipment and processes are optimized for tight tolerances, consistent part quality, and scalable production.
Automated 3D Wire Benders
Our automated 3D wire bending machines form complex, multi-plane geometries in a single continuous process. These systems provide precise control of bend angles and radii, support rapid changeovers, and ensure repeatable accuracy across both prototype and high-volume production runs.
Dual Feed Systems
Dual feed systems allow multiple wire diameters or materials to be run within a single setup. This capability reduces setup time, improves throughput, and supports more complex part designs while maintaining dimensional consistency.
CNC Wire Forming
CNC wire forming equipment enables precise control over cut length, bend location, and forming sequences. CNC-driven processes ensure tight tolerances, minimize variation, and allow fast adjustments to meet evolving design and production requirements.
Our Wire Forming Techniques
- Bending: Forms wire into precise angles, radii, and custom geometries.
- Chamfering: Adds smooth, angled edges to improve fit, safety, and assembly.
- Drawing: Reduces wire diameter while enhancing strength and surface finish.
- Flattening: Converts round wire into uniform flat profiles for specialized applications.
- Piercing: Creates precise holes or openings for fasteners and assemblies.
- Shearing: Cuts wire to exact lengths with clean edges and tight tolerances.
- Swaging: Reduces or tapers wire sections to improve strength and retention.
Trust Our High-Quality Materials
At The Federal Group, we provide high-quality wire forming services using a wide range of materials. Our wire forming capabilities give us the ability to provide our clients with customized solutions to meet their specific needs. We work with a variety of materials, including:
- Alloys made with titanium and nickel
- Aluminum
- Brass
- Copper
- Stainless steel
Each suited to different applications and offering unique properties like corrosion resistance and exceptional strength.
Secondary Operations
TFG offers a full range of secondary operations to complement our wire forming capabilities, enabling customers to receive fully finished, production-ready components from a single manufacturing partner.
- Assembly
- Coining
- Custom Finishing
- Drilling
- Grinding
- Threading
- Welding
Contact Us to Start a Custom Wire Forming Project Today
At The Federal Group USA, we understand the importance of producing quality wire forming products for your business. No matter what your diameter, shape, or wire form may be, our manufacturing processes are developed to meet the needs of your wire products and components.
Contact us today to get started on your next wire forming project.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
