Wire Forming

Process Overview

Wire forming turns solid wire into bends, offsets, loops and shaped components for retaining, positioning, attachment and support. Parts may be planar or three-dimensional, depending on the design and forming route.

Capabilities

Wire diameter, material condition, bend geometry, tooling needs and the production route are confirmed during project review. Typical applications include handles, guide forms, retaining shapes and wire supports. If spring behavior is required, confirm the manufacturing route separately.

Design Considerations

Specify wire diameter or cross-section, material grade and condition, bend radii, angles, leg lengths and end details. State whether radii are measured to the inside of the bend or the wire centerline, and show the orientation of out-of-plane features.

Identify mating parts, critical fit dimensions, finish and any joining or secondary operations. For a part that flexes or carries load, provide the functional requirements and the responsible designer’s acceptance criteria.

Quality

Quality review covers finished shape, end positions, feature orientation and surface condition. Define allowable marks, burrs and end condition. Any force, deflection or fit check needs a measurement method and acceptance limits.