Understanding the Wire Forming Process, Techniques, and Applications

Wire forming is a cornerstone of modern manufacturing, shaping everything from everyday items to critical components in the construction, warehousing, data storage, and medical industries. This versatile process offers unparalleled precision and customization, enabling the creation of products that meet the highest standards. Discover how wire forming drives innovation across industries and transforms raw materials into essential solutions.

Now that we understand wire forming’s impact, let’s explore the step-by-step process and the techniques that make it so versatile.

The Wire Forming Process: What Is It?

Wire forming is a process where wire is shaped into various configurations and products using different types of equipment. Wire forming is widely used in a variety of industries, from  household appliances  to manufacturing wire baskets  and medical devices. Everything from simple components like hooks, clips, and springs to more complex products like fans and oven racks are made using wire forming manufacturing processes. Let’s break down the wire forming process into steps:

1. Drawing: The process begins with drawing, where the wire is pulled through dies to reduce its diameter. This stage is essential to achieve the correct wire thickness needed for further forming steps.
2. Straightening: After drawing, the wire undergoes straightening to remove any curvature, ensuring the wire is properly aligned and ready for precise bending and shaping.
3. Bending and Shaping: Using specialized tools and dyes, the wire is bent at exact angles according to the design requirements. In this stage, the wire can also be flattened or pierced to meet specific component specifications.
4. Precision Forming with CNC and Four-Slide Machines: To ensure parts are precise, consistent, and meet exact specifications, wire forming often involves advanced equipment such as computer numerical control (CNC) and four-slide machines.
5. Final Adjustments and Quality Control Preparation: Depending on the design, additional adjustments may be made to refine the wire’s shape. After forming, the wire may go through heat treatments, coatings, or other finishing steps before quality control inspections.

So, as we can see, wire forming is a multi-step process that can take various forms depending on the complexity of the product. Let’s explore some of the most common methods used to shape wire into precise configurations.

Common Methods in Wire Forming Techniques

While the techniques used in wire forming vary significantly depending on the complexity, precision, and scale of the product, they can be categorized into four main categories. Fundamental techniques include welding and bending metal wires, with finished products requiring anything from flattening and piercing to threading and drilling.

Welding Custom Wire Forms

Two welding processes are generally used to develop custom wire forms:

1. Resistance welding – The resistance process involves sending an electric current through the pieces of wire and using electrodes to join them into custom forms.
2. Metal inert gas (MIG) welders – Metal inert gas involves the use of inert gas and a feeder wire to melt and join pieces of wire into custom forms.

Bending Wire Forms

Image above: An industrial fan manufactured by TFG USA via wire forming.

Bending is generally used to shape pieces of wire into certain configurations, such as turning a piece of wire into a spring. Common bending wire forms machines are:

Single-headed Bending Equipment

The single-headed bending equipment utilizes computer numerical control (CNC) systems to automate the wire bending process. This CNC single-head wire bender is capable of bending complex 3D shapes from wires up to .39 inches or 10 mm in diameter.

Double-headed Bending Machine

Two independent bending heads provide end-users with a powerful wire-bending machine for bending wire alongside bars, plates, and wire-wound resistors. The double-headed machine is also CNC-controlled, thus adding a level of automation to the wire-bending process.

Multi-axis Camless Wire Bending Equipment

Camless 3D wire forming equipment takes advantage of forming software to automate the bending of wire with diameters within the 0.3 mm to 10 mm range. It is a CNC-controlled process that delivers highly precise forms according to requirements.

Flattening and Piercing Wire

Flattening and piercing are processing techniques used to create wire forms or prepare a piece for further bending activities. The process involves the use of a “flatten-punching and wire-bending integrated machine” to execute multiple wire forming activities. Flattening leaves flat surfaces on the piece while piercing leaves holes within the piece.

Threading and Drilling Wires

For applications in which threaded or drilled wire forms are required, the threading and drilling process must be applied. Here, threading, drilling, and milling equipment are used to customize parts according to the requirements.

Secondary Wire Forming Operations

To meet the quality requirements many enterprises desire, wire forming manufacturers, undertake diverse secondary operations to implement designs or finish the surfaces of bent pieces of wire. These secondary operations include:

Shaping or Stamping Operations

Flattening, piercing, or threading processes may be viewed as secondary operations as they involve the inclusion of designed patterns on wire pieces. For the processes of threading, drilling, or piercing, robotic devices equipped with technologically advanced correct tools are used to implement the finish.

Finishing

Applied surface finishes enhance pieces of wire with features or new capabilities suited to the required functionality. For example, electro-polishing removes the first layer of the wire piece, leaving an ultra-clean surface finish that reduces friction and increases the lifespan of the finished piece. Other secondary finishing operations include powder coating, nickel plating, vinyl coating, passivation, and zinc plating.

Packaging Solutions for Optimal Product Protection

Proper packaging of wire forms is essential to ensure increased shelf-life and minimize the need for manual detangling and sorting during use. Customers may request features like packing clasps, strapping packaging, and premium boxes to protect and organize the finished product according to their requirements.

Quality Assurance in Regulated Industries

Industries such as healthcare and medical device manufacturing function under strict regulations to ensure the safety of patients and caregivers. These regulations apply to the use of wire pieces within devices used for these industries. Hence, secondary quality assurance operations such as sterilization and other finishing operations may be part of the wire forming process.

Wire Forming Machines

Wire forming machinery includes traditional equipment that relies on manual labor, semi-autonomous equipment that utilizes computer-aided manufacturing tools, and fully-automated robotic devices to ease the forming process. These pieces of machinery are used to execute simple and complex forming activities alongside other secondary operations. Some of the machines used in manufacturing  wire forms include:

3D Wire Forming Machinery

This refers to CNC 3D wire forming machines that are used for high-speed and precision manufacturing or forming of 3D wire forms. This equipment is capable of executing operations such as threading, punching, piercing, and heading when required. Above is an image of a 3D wire forming machine courtesy of BLM Group.

2D Wire Forming Machinery

This refers to 2-dimensional CNC-forming machines for making 2D wire forms. The machine utilizes cutting, punching, and piercing tools.

Tabletop Benders

Desktop or tabletop bending machines are used for smaller wire welding tasks and may include the use of either a hydraulic or pneumatic system to provide the necessary bending force.

Four-slide Machines

The four-slide machine is used to produce small stamped wire forms for large-volume production runs. The machine includes a stamping press and an electric motor to execute stamping operations.

Spring Coiling Machinery

Spring coiling machinery, which may include both manual and CNC-operated coilers, is used to produce a wide variety of custom wire forms and springs. With multiple axes (2, 4, 6, or 8), CNC spring coilers allow independent control over tooling positions, enabling the creation of complex, custom wire forms.

What is CNC Wire Forming?

CNC wire forming is a specialized process that provides unmatched precision and flexibility for creating complex wire designs. When high precision and the need to create complex designs from pieces of wire is the goal, CNC wire forming provides the best technical capabilities for achieving these goals. CNC wire forming machines utilize computer numerical control systems to form highly accurate 2- or 3-dimensional wire forms using cutting, drilling, and bending tools.

The utilization of CNC systems and programming introduces an aspect of autonomous digital control no other wire forming manufacturing process can match. CNC wire forming excels at producing custom designs and configurations at high accuracy for mid- to large-volume production runs while reducing material waste.

With a clear understanding of the machinery, let’s take a look at the types of wire forms these processes create and the industries that rely on them. From springs to wire baskets, the possibilities are endless.

Types of Wire Forms and Their Applications

The versatility of wire forming lends itself to crafting many types of products. From industrial machine parts to consumer products, wire forms play critical roles in various industries. These products can be formed into countless shapes and configurations to meet specific design requirements.

Wire Forms for Industrial Use: Springs, Clips, and Hooks

In industrial settings, wire forming is essential for manufacturing components like springs, clips, and hooks. These parts must be durable and reliable, capable of handling intense use for long periods under extreme conditions.

Springs are one of the most common wire formed components. In industrial use, springs are made to precise specifications, capable of handling repeated use, providing compression, absorbing shock, and maintaining stability. Clips are also common in industrial machinery. Often used to secure parts and maintain alignment in engines and hydraulic systems, clips must be versatile enough to stay in place during operation while also easily removed when needed.

Industrial hooks, including S-hooks and swivel hooks, are made in various shapes and sizes, to perform a wide range of functions. Wire formed hooks for industrial use are designed to withstand heavy loads under extreme conditions.

Wire Baskets, Screens, and Guards: Protecting and Organizing Spaces

The production of wire baskets, screens, and guards involves several wire forming methods, including wire bending, welding, and forming. These products are used in a variety of industries, including manufacturing and food processing. Wire formed baskets are also used in retail and healthcare settings to organize products.

In agriculture, wire screens and guards are used for sorting crops, protecting plants, and ensuring airflow during food storage. Heavy-duty wire formed screens may also be found on agricultural equipment to protect operators from injury.

Wire formed products are versatile and flexible. Once you understand the benefits and applications of components like baskets and screens, it becomes clear why they are essential in so many industries.

Custom Wire Forms for Unique Applications

Able to be crafted into a wide range of configurations, wire forms offer limitless possibilities and applications. Manufacturers can tailor the design to solve unique challenges, enhance performance, and meet industry standards. From simple shapes like rings and hooks to complex designs like cages and screens, there are numerous ways to customize wire forming to meet your exact needs.

Some examples of unique applications for wire forming include lightbulb filaments and battery contacts. Clock parts, musical instrument components, and all sorts of rivets and pins are made with wire forming. In the medical field, wire stents and orthopedic supports are made with wire forming. And in the automotive industry, exhaust hangers and wire brackets are often made using this versatile metal manufacturing method.

While wire forms come in all shapes and sizes, the material chosen for the wire is just as important. Different materials bring unique properties to the final product, impacting its strength, durability, and performance in specific environments.

Exploring the Materials Used in Wire Forming

Another way that manufacturers can tailor the design of wire forms is by using different wire materials, including alloys like stainless steel and metals such as copper and aluminum. Explore the various materials used in wire forming and learn how their specific properties impart characteristics such as corrosion resistance and durability to the final product.

Common Materials: Aluminum, Copper, Steel, and Alloys

The most common materials for wire forming include aluminum, copper, steel, and alloys. Here are the unique characteristics and benefits of each wire material:

• Aluminum: An ideal choice for many types of wire formed products, aluminum is a relatively cheap metal when measured by volume. It’s an abundant material known for being lightweight and conductive, making it a good choice for wire formed electrical parts. It’s also ideal for aerospace applications, where weight is a critical issue.
• Copper: Highly valued for its malleability and conductivity, copper is expensive. It’s used in decorative fixtures, plumbing, and electrical applications. Copper’s natural resistance to corrosion adds to its versatility.
• Steel: An iron alloy, steel is strong and cost-effective, making it a top choice for wire forming parts and components that need exceptional durability. It may need to be coated to prevent oxidation, depending on the application.
• Other alloys: Various alloys offer specific properties for different uses. Brass and bronze are common metal alloys used in wire forming, often selected for being strong and anti-corrosive.

Stainless Steel Grades: 304, 316, and 434

Stainless steel, which was invented in the early 1900s as a solution to the problem of rust, is an ideal material for many wire formed products. Because it doesn’t corrode, it’s often used in making food-safe equipment and medical devices that require strict hygiene standards. It’s also used in aerospace and automotive applications because of its durability and ability to withstand extreme temperatures.

There are over 100 grades of stainless steel, but when it comes to wire forming, these are the three most commonly used grades:

• 304: Widely used for brackets, shelves, and springs. Grade 304 is a versatile and cost-effective choice.
• 316: This grade, with its higher resistance to chlorides and corrosive environments, is ideal for marine and chemical applications
• 434: Commonly used for automotive clips, brackets, and exhaust components due to its heat resistance

Choosing the Right Material for Your Wire Forming Needs

Choosing the right material for your wire forming project is critical to its success. You must evaluate strength requirements and consider factors like environmental conditions. Cost is another important consideration, especially for high-volume production runs, but you must factor performance issues into the equation as well. In some cases, industry standards and regulatory compliance issues dictate the types of material you can use.

Making an informed choice is easier if you consult with material specialists and experienced metal manufacturers who understand the properties of various metals and alloys. At TFG USA, our experts can recommend a suitable material for your application, balancing performance, durability, and budget constraints.

Industries and Applications

Custom wire forms play a crucial role in a wide variety of industries, offering versatility, precision, and reliability. From intricate medical devices to robust automotive components, wire forms provide essential solutions tailored to meet the demands of each sector. Below are some key industries that rely on wire forming:

• Aerospace Industry: Wire forms are used in the creation of door handles, seat frames, and instrumentation systems that must endure extreme conditions and precise performance standards.
• Agriculture Industry: Wire racks, shelving, and fencing are essential in supporting livestock control, crop sorting, and equipment organization. Wire baskets and screens also protect plants and enhance airflow during storage.
• Automotive Industry: From seat frames to spring mechanisms, wire forms are critical in vehicle assembly. Exhaust hangers, wire brackets, and custom clips ensure the durability and functionality of various automotive components.
• Construction: Wire forms serve as protective barriers and structural supports in construction, ensuring safety and stability across a range of building applications.
• Data Centers: Wire forms provide cable management solutions, including server racks and power control components, helping keep data centers organized and efficient.
• Healthcare Industry: Sterile storage shelving, medical device components like stents, and wire baskets for surgical instruments depend on wire forming’s precision and safety standards.
• Electronics and Industrial Engineering: Wire forms play a key role in electrical fittings, industrial casings, and storage lockers, supporting both internal and external infrastructure needs.
• Household Products: Everyday items like fans, barbecue grills, dishwasher racks, and wire shelving are made possible through wire forming, combining durability and functionality for domestic use.
• Retail and Warehousing: From shopping carts to security gates, wire forms enable efficient organization and security in retail spaces. Point-of-purchase displays and store fixtures also rely on custom wire forms for their versatility and strength.

Choosing the Right Wire Forming Solutions for Your Needs

When it comes to finding a wire forming company, it’s important to choose someone who offers customization, advanced technology, and experience in delivering complex designs and high-volume production.

At TFG USA, we use advanced manufacturing methods and precision wire forming equipment to create high-quality, custom wire forms. We have experience working across various industries, ensuring consistent quality and performance.

Contact our engineering team today to discuss your wire forming needs and discover the advantages of our tailored solutions and experience.