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Wire Forming: Types and Uses

Chapter One – What is Wire Forming?

Wire forming refers to the process of reshaping wire by applying force through various techniques such as bending, swaging, piercing, chamfering, and shearing. Using these methods enables the creation of diverse shapes, configurations, and forms. The procedure commences with coiled wire, which is first straightened and then formed into the desired shape.

Commonly utilized metals in wire forming include steel, brass, stainless steel, copper, aluminum, along with assorted alloys. Wire diameters typically vary from 0.5 mm to 6.5 mm (1/64 inch to 0.25 inch) and can be molded into both two-dimensional and three-dimensional structures.

Wire forming equipment can range from basic handcraft tools to sophisticated CNC programmable machinery. Furthermore, the process includes options for finishing techniques like coating to protect and enhance the endurance of the final products against challenging environmental conditions.

Chapter Two - Methods Used for Wire Forming

Wire forming is an essential process in the metal fabrication and manufacturing industry, used to produce custom wire components, wire parts, and metal forms for a wide range of applications. There are various types of equipment used for wire forming, generally falling into manual or automatic categories. Manual machines include those operated by hand as well as semi-automatic models that, while electronic, require manual wire loading and adjustment. In modern industrial settings, automatic wire forming machines—often featuring advanced computer numerically controlled (CNC wire forming) programming—handle the entire production process without the need for direct human intervention, greatly increasing efficiency and precision. These automated systems are in high demand in high-volume production environments for creating precision wire forms, springs, fasteners, and intricate wire products.

Drawing Method

Before wire forming can begin, the raw metal wire is processed using a wire drawing method to achieve the desired wire diameter, cross-section, and material properties for the final product. This critical wire drawing operation involves pulling the wire through a series of dies, which are typically funnel-shaped and crafted from hardened steel or carbide. As the wire passes through the die or multiple dies (known as multiple pass drawing), the pressure exerted by the die sides incrementally reduces the wire's diameter, while simultaneously increasing its tensile strength, hardness, material uniformity, and length. This tightly controlled process results in high-quality drawn wire suitable for subsequent forming, bending, coiling, or stamping operations.

The Drawing Process

1. Install the Drawplate: The drawplate, a key part of any wire drawing setup, must be securely installed to offer the necessary leverage. Drawbenches, especially specialized drawbenches designed for the process, are normally used in both artisan and industrial wire forming shops.
2. Tapering: One to two inches (2.5�5 cm) of the wire must be tapered before insertion into the die, ensuring smooth entry and even diameter reduction throughout the pulling process.
3. Annealing: Annealing the wire before drawing prevents breakage and cracking during diameter reduction. In most cases, after annealing, the wire is pickled (cleaned) to remove surface oxidation and scale.
4. Lubrication: A range of lubricants—including dry powders, oils, or soaps—are available to minimize friction and make the movement of the wire through the die smoother, prolonging die life and improving surface finish.
5. Pull Through: The tapered end of the wire is inserted into the unmarked side of the drawplate and gently pulled through, often using mechanical force to achieve the required gauge for forming operations.

Methods Used to Form Wire

Wire forming employs multiple specialized metal shaping processes, each tailored to produce specific shapes, wire patterns, custom wire forms, or complex configurations. While these methods overlap with other metal part manufacturing techniques, they have been optimized for continuous, high-precision wirework in industries such as electronics, automotive, medical device manufacturing, and custom metal fabrication.

Manual Wire Forming

The oldest method of wire forming utilizes manually operated wire bending machines, which use a hand lever and spindle for shaping. These manual machines may feature either draw or rotary dies and come equipped with high-torque gears that enhance the bending force applied to the steel wire or other metal, allowing operators to create simple or complex bends for prototypes and small batch production.

Coil Wire Forming

Coil or spring wire forming is fundamental to spring manufacturing, electrical coil production, and custom torsion applications. This method involves winding wire uniformly around a metal blank, mandrel, or ferromagnetic core. Electrical coil production requires high precision to achieve exact inductance and resistance, often using automated coiling machines for consistent results. The coiling process—critical in producing compression springs, extension springs, and torsion springs—varies based on end-use requirements such as load specifications and electrical properties.

Roll Wire Forming

Roll forming is a continuous, cost-effective manufacturing method for producing flat, round, or complex-shaped wire parts. Using sets of precisely aligned rollers, this process forms the wire into desired profiles, including wire undercuts, knurls, points, chamfers, grooves, specialized surface finishes, collars, and threads. Roll-formed wire components often exhibit increased tensile strength and springback resistance after hardening, along with smooth, rounded edges and prefinished surfaces, making them ideal for high-strength applications such as automotive clips, clamps, and metal brackets.

Bending Wire Forming

In the wire bending process, wire can be shaped into a wide variety of custom configurations—including 2D and 3D forms—to suit nearly any industrial or commercial application. Wire diameters ranging from 0.016 inches to 0.635 inches (0.4 mm to 16 mm) can be easily formed. Because the bends are made before the wire is cut, this process generates virtually no scrap or waste and eliminates the need for secondary finishing. Advanced wire bending equipment—from simple hand tools to sophisticated servo-driven CNC wire benders—deliver precision and speed for forming intricate assemblies, wire racks, display hooks, safety pins, and more.

Fourslide Wire Forming

Fourslide forming (also known as multi-slide stamping) utilizes a horizontal stamping press equipped with additional cams to create complex, multi-plane wire shapes. The fourslide machine includes shafts, an electric motor, a die, a press, and four sliding tools. The cams precisely control the movement of these sliding tools, enabling both vertical actions such as punching and horizontal wire manipulation in synchrony. This multi-directional forming capability provides immense versatility for creating intricate wire forms, terminals, electrical connectors, and clips for mass production.

The fourslide process offers a high-speed alternative to traditional stamping by rapidly producing small, complex forms with minimal material waste. Unlike conventional unidirectional stamping, it can shape metal strips or wires from four sides simultaneously, resulting in enhanced component uniformity and cost efficiency in high-volume manufacturing.

Hydraulic Wire Forming

In a hydraulic wire forming machine, powerful hydraulic motors drive the shaping rollers and tooling assemblies. The machine, often integrated with a servo motor and CNC controls, is capable of high-torque forming of heavy-gauge wire and custom metal rods for demanding applications such as automotive suspension, construction reinforcement, or industrial enclosures. Once the programmed operation is complete, formed wire parts are automatically ejected for high productivity.

Pneumatic Wire Forming

In the pneumatic wire forming process, wire is efficiently fed into a straightening machine, shaped to the desired form through pneumatic (compressed air-powered) mechanisms, and cut to length. This method is preferred in environments where rapid, repetitive forming of uniform wire parts is required, such as in the production of fasteners, hooks, hangers, and wire supports. Pneumatic systems offer high-speed throughput and low maintenance requirements.

CNC Wire Bending

CNC wire bending machines—available in pneumatic, hydraulic, and electric servo-driven configurations—provide unmatched efficiency and precision for rapid production of custom wire forms and prototypes. These automated machines are engineered to accurately bend and shape wire, including rebar, up to 180° in single or double wire operations and are capable of straightening the bar prior to the forming process for optimal results.

Advanced CNC wire forming machines feature programmable logic controls for exceptional accuracy and consistent, repeatable results, precisely cutting and shaping wire to exact dimensions. While sometimes slower than dedicated high-speed formers for large production runs, CNC systems excel in flexibility, ideal for low-volume production, prototyping, or manufacturing complex geometries that would otherwise require expensive tooling. Modern CNC benders can be programmed for a broad range of materials, including music wire, hard-drawn steel, galvanized or coated metals, 300 series stainless steel, brass, copper, and even exotic alloys such as titanium or beryllium copper. The supported diameter range typically spans 0.008 inches to 0.250 inches (0.0203 mm to 6.35 mm), covering most wire forming requirements for industrial and custom use.

Wire Ends and Interior Geometries

The finishing of wire ends and formation of specialized geometries are critical steps in custom wire forming, directly impacting a part's fit, function, safety, and usability. Accurate end finishing and interior shaping often enhance the wire's performance in assembly operations or as a finished component in a larger system.

Machine Cut End

Wire ends can be cut straight with minimal burrs or finished with a clean, burr-free cut. Other options include quill or angle cut ends, where a single angle or opposing angles are applied for specific assembly and penetration applications.

Chamfered End

Chamfered ends have a smooth, flat slope machined around the wire tip to remove sharp edges. This process is commonly used for safety-critical parts and to facilitate easier insertion into mating components.

Winging

Winging, also called swaging, involves placing the end of the wire in a special die that forms a wing shape. This configuration improves component retention or engagement for fasteners, clips, and specialty hardware.

Pierced Swaging

In pierced swaging, wire ends are first swaged to create an expanded geometry, after which a hole is precisely punched in the center. This method is popular when producing wire lugs, electrical contacts, or custom fittings where mechanical or electrical connections are required.

Custom Shaped Hole

For parts needing specialized connections or unique mounting requirements, a custom-shaped hole can be created. The end of the wire is trimmed by a die and then a shaped punch is used to form the desired opening.

Chisel Point and Turned End

In this process, specialized dies create a jagged or pointed end by cutting the wire on a precise diagonal. Chisel points are common in pins, stakes, and probes for easy penetration into other materials.

Ball End

A lathe or automatic turning machine forms the end of the wire into a smooth, rounded ball—often used for decorative elements, electrical contacts, and mechanical detents.

Groove

In the groove end process, a controlled circumferential groove is machined or pressed into the wire's end, which can help with locking, assembly, or securing components in hardware systems.

Cold Heading

Cold heading is a forging process in which the wire is subjected to a series of high-force blows that flatten or round the end. This results in robust button, carriage, or collar-head styles, often seen in screws, rivets, or fasteners where strong, uniform heads are required.

Wire Forming Tolerances

Adhering to precise wire forming tolerances is crucial in all metal fabrication and manufacturing processes—especially in wire forming where even small dimensional deviations can affect product fit, function, and quality. Wire forming tolerances are typically ±0.01 per bend or ±0.06 on an assembly. More stringent tolerances may require advanced CNC machines, specialized tool and die setups, additional secondary operations, and extensive engineering review. Meeting or exceeding industry standards for dimensional accuracy is vital in sectors like aerospace, automotive, medical device assembly, and custom metal part production, ensuring components function reliably as part of larger assemblies. See the chart below for standard wire diameter tolerance values across metric and imperial units.

When seeking a wire forming partner or sourcing custom wire forms, buyers should also consider factors such as material selection (e.g., stainless steel, carbon steel, copper, titanium), surface finishing, secondary processing (such as threading, welding, or assembly), production capabilities (including short-run vs. high-volume), in-house engineering support, quality certifications (e.g., ISO 9001), and lead time. Leading wire forming companies invest in advanced automation, state-of-the-art tooling, and stringent quality control measures to meet the diverse needs of industries like aerospace, medical, electronics, and industrial equipment manufacturing.

Leading Manufacturers and Suppliers

Chapter Three - Types of Wire Forms

The range of wire shapes, configurations, and forms is virtually limitless, with new ones continually being developed. Wire forming can create anything from complex, intricate three-dimensional designs to simple hooks and springs. Many of the items we use daily incorporate some form of wire forming.

Types of Wire Forms

Hose Clamps

Wire hose clamps are made from heavy wire bent into a U shape and then formed into a ring with one end overlapping the other. The ends are bent upward to allow for opening. When the ends are pushed apart, the clamp tightens around the hose, applying even pressure to prevent leaks. To loosen the clamp, the ends are pushed together.

J Hook

There are many types of J hooks, with the fishhook being one of the most common. They can be coated to protect the materials they hold and often feature notches for hanging. Double J hooks, when attached to a strap, are capable of supporting substantial loads.

Linchpins

Linchpins are inserted into the end of an axle to prevent wheels from coming off. They are made from aluminum, zinc, brass, and stainless steel.

R Clips

R-clips, also known by various names, are metal wire fasteners shaped like the letter R. They function similarly to linchpins, securing the end of an axle or rod with a wheel. The long, straight portion of the clip fits through a hole at the end of the shaft, while the springy part loops over the shaft at the top or bottom. The semi-circular, bent section of the clip fits snugly around the shaft. To facilitate insertion into the shaft's hole, the end of the semi-circular part is bent upward, as shown in the image below.

S Hook

Both ends of an S hook are bent to form the S shape. They are normally used for hanging storage or for organizing cables, hoses, and cords as a safety measure.

Springs

Among the various wire forms, springs are the most common and widely utilized. They consist of a coil wound into a tightly wrapped spiral to achieve specific tension requirements. The type of spring chosen depends on its intended use and application.

Threaded Wire Forms

In the wire form threading process, a metal rod is passed through a set of threading dies that shape the threads with peaks and valleys. This method produces high-strength threads quickly. Unlike rolled threading, which forms threads by rolling the metal, cut threading removes metal from the workpiece to create the threads. This method allows for a wider range of diameters, thread lengths, and pitch combinations.

Utility Hook

Utility hooks feature a threaded end and a hook, making installation straightforward. The manufacturing process involves several bends, including offset bends on both sides of the loop and a final bend at the end of the loop that touches the opposite side.

Wire Baskets

Wire Baskets are used for bulk storage of parts, equipment, and components. They are made of a welded wire mesh. Some forms have a rust-resistant electrogalvanized finish to prevent wear and rusting. The open mesh design provides excellent strength, inventory control, visibility, and forklift access. In production facilities, they can be used to strategically place parts for easy access.

Wire Displays

Wire displays are a durable and cost-effective solution for showcasing products. They are manufactured by bending, shaping, and forming wire made from low, medium, or high carbon steel, as well as from stainless steel, copper, and aluminum brass. After the wire is formed, it can be coated, plated, or painted to enhance its appearance and durability.

Wire Guards

Wire guards come in various forms, all designed to prevent access to equipment, passageways, instruments, and sensitive materials. Hinged wire guards, or wire cages, are used to protect sensitive equipment in high-traffic areas, such as manufacturing locations and athletic fields, from potential damage. Open-face wire guards prevent accidental activation of fire alarms or emergency stop switches. Additionally, they are used to enclose automated and robotic machinery, tanks, heavy equipment, motors, and spiral HVAC fans, ensuring safety and security.

Wire Screens

Wire screens Thin metal wires are woven horizontally and vertically to create an open protective barrier that limits access and material flow. These intersecting wires are either welded or woven. The wire is shaped to the appropriate diameter using various wire-forming processes. In the welding process, a preprogrammed machine welds the rows and columns together at their intersections. In the woven wire screen process, the wires are woven in a manner similar to cloth, passing over and under each other at perpendicular intersections.

Z Clip

Z clips are utilized to securely lock components in place. The extended portion of the Z clip slips over the item to be secured and is anchored at both ends to ensure a firm hold. They are available in various thicknesses and diameters to suit different applications. Very small Z clips are used to hold electronic computer components. The advantages of Z clips include their strength, versatility, and resistance to corrosion.

Chapter Four � What Are The Wire Forming Materials

Wire forms can be fabricated from a wide variety of metals, including aluminum, copper, steel, brass, stainless steel grades 304, 316, and 434, as well as various types of alloys.

Bright Basic Wire

Bright basic wire (BBW) is a low carbon steel wire with a bright polished finish. It is cold drawn to enhance its tensile strength and mechanical properties. BBW possesses the essential physical properties for bending, straightening, welding, and finishing with epoxy, plastic, galvanization, or powder coating. The common grades of BBW used for wire forming are 1008C and 1018C.

Galvanized Wire

Galvanized wire is carbon steel wire coated with zinc through electroplating or hot-dipping. This process makes it rust-resistant and exceptionally strong, and it is available in various gauges. In the hot-dipping process, the carbon steel wire is submerged in a zinc bath. Upon removal, the wire cools and reacts with the surrounding oxygen, binding the zinc to the carbon steel.

Stainless Steel 304

Stainless steel grade 304 has high resistance to corrosion with a tensile strength of 621 MPa and can be used in conditions with mild corrosive elements or where handling of heavy loads is required. The quality of grade 304 makes it durable and long-lasting. It can be used in conditions that have temperatures that exceed 1500° F (815.5° C) less than 2500° F (1371 ° C). It may be important for some applications that none of the 300 grade stainless steels are magnetic.

Stainless Steel 316

Grade 316 stainless steel is more resistant to corrosion and can withstand the effects of chlorides. It has a tensile strength of 579 MPa and can handle extremely heavy loads. Grade 316 can be used in environments with temperatures that do not exceed 1400° F (760 ° C). Its ability to withstand caustic or highly corrosive environments has made it extremely useful.

Stainless Steel 434

Stainless steel grade 434 is a ferritic alloy that is resistant to pitting and does not have any nickel content, which makes it less expensive. A restriction on stainless steel grade 434 is the temperatures at which it can be used, less than 1500° F (815.5° C), limiting its use for heat treatment applications. It is highly resistant to oxidation, corrosion, and pitting and is very useful in the production of industrial baskets.

Brass Wire

Brass is an alloy consisting of 67% copper and 33% zinc, retaining the electrical and heat conductivity and malleability of copper. It is stronger than copper, making it suitable for a wider range of applications, including wire forming. Certain brass alloys include elements like antimony, arsenic, iron, and tin to enhance mechanical and physical properties such as hardness, formability, strength, and appearance.

Copper Wire

Copper (Cu) is a soft, malleable, and ductile metal with high electrical and thermal conductivity and a reddish-orange hue. Its excellent conductivity and ease of shaping make it ideal for wire forming. Copper is resistant to rust and corrosion, and over time, it develops a green patina when exposed to the atmosphere.

Aluminum Wire

Aluminum (Al) is a soft, non-magnetic, and ductile metal, making it the third most abundant metal on Earth. It is derived from bauxite and often occurs in combination with over 270 other minerals. Aluminum is known for its low density and resistance to corrosion. For wire forming applications, aluminum is alloyed with other metals because it is prone to deformation in its pure form. Key alloying metals include copper, zinc, magnesium, manganese, and silicon.

Steel Wire

Steel is an alloy of iron with added carbon to enhance its strength and resistance to fracturing. Its primary appeal in manufacturing lies in its high tensile strength combined with affordability. The base metal of steel is iron, and the interaction between iron's allotropes and its alloying elements, primarily carbon, imparts the steel's properties. Since pure iron is soft and ductile, the addition of carbon and other alloys increases its hardness, strength, and durability.

Chapter Five � How Are Wire Forms Used?

Wire forming is a key process in industries that utilize wire to create components and parts. This technique encompasses both standard shapes and custom-designed forms, making it highly adaptable to various conditions, materials, and engineering requirements.

Uses for Wire Formed Parts

Medical Uses

Parts for the medical industry must be durable, smooth, and exceptionally clean. Stainless steel is the primary metal used for manufacturing medical components because it can endure high temperatures, repeated cleanings, and sterilization. Its smooth surface helps prevent nicks, cuts, and punctures to medical workers' gloves and garments.

Industrial Uses

Industrial operations demand fast and precise methods for assembly and manufacturing. Wire-formed baskets play a crucial role in the efficient and organized delivery of parts to production areas, ensuring convenience and speed in handling.

Automotive Uses

In the automotive industry, wire forming encompasses a range of components including wire springs, compression coils, and volute springs for suspension systems. Delicate springs, such as torsion and tension springs, serve various functions, including supporting swing-down tailgates. Additionally, conical springs are used in manufacturing battery contacts.

Athletic Uses

Masks used in contact sports are wire-formed for protection and are designed to meet the standards set by the National Operating Committee on Standards for Athletic Equipment (NOCSAE).

Telecommunications Uses

Steel wire is utilized for guides and trays due to its smooth surface. The open design facilitates easy access for cable installation, inspection, and upgrades. Routing rings can be attached to frames to manage various types of wire, thanks to the strength of the wire frame. Trays, troughs, and support hardware are designed for efficient cable management, incorporating routing rings and tie bars for optimal organization.

Retail Uses

A common use of wire forming in retail is product display racks that are lightweight but sturdy enough to hold products for customer inspection. They can be placed at cash registers as point of purchase displays or in multiple locations throughout the store. Their light weight makes it easy to relocate them to high-traffic aisles. Wire racks are also a convenient way for storing merchandise for future sales and conducting inventory.

Food Uses

The food industry must adhere to numerous regulations to comply with FDA requirements and specifications. Wire storage and processing racks must meet stringent standards for sanitation and cleanliness. They are constructed from high-grade stainless steel, which is corrosion- and rust-resistant, and capable of being continuously sanitized and washed.

Construction Uses

Wire forms play a crucial role in building construction, serving various functions such as holding wires, supporting hooks, springs, pins, wire guards, equipment frames, and wire screens. They are used not only as essential construction materials but also in decorative applications, including guardrails and accent pieces.

Chapter Six � What Are The Wire Forming Process Details

The wire forming process involves four key steps that should be considered when deciding to wire-form a part or component. These steps include selecting the appropriate type of wire for the application, straightening the wire before processing, applying force to shape the design, and determining if secondary processing is required.

Wire Form Process

Wire Selection

The gauge, diameter, and type of wire used in the wire forming process are determined by the initial CAD design. Steel and stainless steel are commonly used for applications requiring durable and long-lasting components, while lightweight wires like aluminum and copper are suitable for less demanding conditions. Wire can be made from low, medium, and high carbon steel, as well as stainless steel, aluminum, copper, brass, and various alloys.

Wire Straightening

Wire is stored in coils and must be straightened before processing. This step removes stress deformities that may have developed during storage. Machine rolling is used for straightening the wire. Uncontrolled irregularities in this process can result in poor wire form.

Applying Force

Wire forming involves applying force to alter the contour and shape of the wire into the desired form. This shaping process is designed to create a diverse range of shapes and configurations. Force can be applied manually or using various automated equipment, including dies and cutting tools. For high-volume production, CNC machines and four-slide machines are commonly used.

Finishing Wire Exterior

The need for finishing in wire forming depends on the type of product and its design. While some wire-formed products may not require additional finishing, others might need post-production adjustments such as cuts, grooves, heading, coining, or swaging. The primary focus of finishing is to ensure that burrs and sharp edges are smoothed out and removed.

Conclusion

• Wire forming is a process for adjusting the contour of straightened wire to achieve a unique shape or design.
• The wire forming process uses several different metals including stainless steel, steel, aluminum, copper, brass, and alloyed metals.
• Wire forming is used by several manufacturing operations that include automobile production, medical equipment, food production, and shipping and handling.
• The types of equipment to complete wire forming vary between manual crafting to advanced CNC programmable machines.
• There is an endless variety of wire forms, which increases regularly as new uses and applications are developed.

Leading Manufacturers and Suppliers