Wire Forming Guide

Wire forming refers to the process to form metal wires (sometimes tubes) into specific shapes or configurations. This process is applied to manufacture parts and accessories such as spring coils, wire fasteners, pins, etc. These parts are called wire forms and used in industries such as appliances, automotive, electronics, and more.

There are many approaches to perform wire forming, ranging from presses, power benders, manually operated benders to the highly advanced CNC forming machines. The forming method and material are selected based on the volumes, physical characteristics, tolerances, designs, and applications of the products.
 

Materials that Wire Forming Processes

Wire forming best handles soft materials such as aluminum, copper, brass, low-carbon steel, and medium-carbon steel. Stainless steel is also commonly seen in wire forming. In some applications, it processes more brittle materials such as high-carbon steel. In essence, wire forming is able to deal with most alloys.

Stainless Steel Wire

Methods that Perform Wire Bending

There is a number of wire forming methods available today. Manual wire forming is the oldest technique. It requires an (or multiple) operator to control a manual bender. The manual method is primarily for low productivity and low tolerance operations.

Roll forming, bend forming, and fourslide forming are common methods that make small wire forms such as fasteners and machine tool accessories. CNC forming excels at high-tolerance 2D/3D wire forming processes.
 

Industries that Require Wire Forming

The industries that rely on wire-forming techniques include medical, industrial, automotive, retail, sports, food, construction, and electronics, just to name a few. Wire forms are found in almost every corner of our daily life. Wire fences, wire masks, wire baskets, wire racks, spring coils, machine structural supports, etc. are all made by wire forming and they are everywhere.
 

What is the Wire Forming Process?

The wire forming process goes like this: wire straightening, feeding, forming, and finishing. Before the process, there are design and material selection. Manufacturers of wire forms come up with wire form product designs and select the material for the products. After the material is chosen, the forming method will be determined and the process initiated.

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