Library
Wire form processes
Deep pages for each operation — how it works, when to use it, and what the print should say. Production is 4–14 mm. Forming first, then prep, join, and finish.
Start with 4–14 mm heavy wire, 3D CNC, shapes, or the USA overview.
Forming
- Heavy wire forming (4–14 mm)We run thisThe 4–14 mm band: frames, wire baskets, guards, and 3D CNC forms that light spring cells cannot run.
- 3D CNC wire formingWe run thisProgrammable bends in multiple planes for 4–14 mm wire — frames, hooks, routing parts, and wire-basket geometry.
- 2D CNC wire formingWe run thisAll bends in one plane. Faster programming, simpler tooling access, and the right choice when the part is flat.
- Wire form shapesWe run thisThe centerline: cut-to-length, L, U, J, S, C, V, serpentine, eyes, rings, and closed frames in 4–14 mm.
- Fourslide / multislideExplain onlyCam tooling for frozen high-volume 2D forms. Explained here so CNC is not sold for the wrong job.
Wire prep
Secondary operations
- End formingWe run thisChamfer, coin, flatten, pierce, swage, and thread so the wire end mates to a hole, screw, or weld.
- Heat treatingExplain onlyStress relief of the form, and why heat-treat wire baskets are a product — not the same as running a furnace on every job.
- Plating and coatingWe run thisRack zinc, zinc-nickel, and zinc-iron, then in-line powder — or dual coat. Pre-coated wire vs post-form finish on 4–14 mm.
- InspectionWe run thisFixtures, overlays, and CMM for 2D and 3D wire forms. Put tolerance on the interface, not on every leg.
Joining
- Resistance weldingWe run thisCross-wire and projection welds that close a form or attach a second piece without filler metal.
- MIG / TIG assemblyWe run thisTack and fusion welds for frames and fixtures when resistance weld is the wrong joint or the wrong alloy.
- Mesh grids and cable traysWe run thisWelded wire mesh, guard grids, and cable trays — resistance, MIG, and TIG after the form.