Sizes we run
3/8, 7/16, and 1/2 inch wire
These three diameters are the stock production sizes on the floor. They sit in the middle of the 4–14 mm band — heavy enough for frames, grids, and trays, still CNC-formable.
Stock production sizes
The library is written for 4–14 mm (0.157–0.551 in). Quotes most often land on these three US fractions. Metric coil that matches is accepted; call the actual diameter on the print, not “equivalent.”
| Fraction | Decimal | Metric | Typical work |
|---|---|---|---|
| 3/8 in | 0.375 in | 9.53 mm | Frames, cable-tray wire, S-hooks, medium mesh rims, guards |
| 7/16 in | 0.4375 in | 11.11 mm | Heavier frames, wire-basket rims, J-hooks, structural grid borders |
| 1/2 in | 0.500 in | 12.7 mm | Structural wire, heavy trays, D-rings, rod frames, furnace fixtures |
Carbon, stainless, and coated wire in these diameters. Full grade list: materials. Finish and weld follow the print — resistance, MIG or TIG — not a default by size.
3/8 in (9.53 mm)
The workhorse. Light enough for a dense mesh or cable tray, stiff enough for machine-guard frames and 2D/3D forms that a 4–6 mm clip wire cannot be. Inside radius starts at 3/8 in on mild carbon; stainless wants more.
- Cable-tray longitudinals and medium-pitch mesh
- Guard frames, handles, and planar outlines
- Wire-basket rims when the infill is lighter than the border
- 3D hooks and routing that still have to carry load
- S-hooks and planar J-hooks
Resistance cross-wire is routine at 3/8. MIG corners on a rim are the usual secondary. TIG when the rim is a jump up in diameter or the alloy is picky.
7/16 in (11.11 mm)
The step between “tray wire” and “structural.” Used when 3/8 sags on the span and 1/2 is more steel than the assembly needs. Same CNC family as 3/8; straightener, cutoff, and weld force all go up.
- Heavier frames and grid borders
- Wire-basket and rack rims
- Short, high-load tray runs
- Guards that take a hit, not just a look
- Mining J-hooks and heavier hangers
Do not substitute 7/16 for 3/8 (or the reverse) to “use stock.” Hole patterns, weld nuggets, and min legs all move. A running change of 1/16 in is a new first article.
1/2 in (12.7 mm)
Near the top of industrial wire CNC — under the 14 mm (0.551 in) ceiling, above most brochure 12 mm heads if the path is tight 3D in stainless. Treat 1/2 in as fabrication that happens to start as wire: real inside radius, real legs, saw or heavy shear on the end.
- Structural frames and rod-style fixtures
- Heavy cable-tray sides and load-bearing rims
- Heat-treat / furnace frames in high-temp alloy
- Guards and decks where 7/16 still flexes
- Heavy D-rings and load-bearing closed forms
Cross-wire resistance weld still works on 1/2 × 1/2; confirm the cell. Corners and mounts are MIG or TIG. A “clip-style” flatten on a 1/2 in end is the wrong picture — see end forming.
Radius and legs at these diameters
| Size | Min IR (mild carbon) | Min IR (stainless / high-tensile) | Min straight between bends |
|---|---|---|---|
| 3/8 in | 3/8 in | ~9/16–3/4 in | 3/4–1-1/8 in |
| 7/16 in | 7/16 in | ~5/8–7/8 in | 7/8–1-5/16 in |
| 1/2 in | 1/2 in | ~3/4–1 in | 1–1-1/2 in |
Full rules: design for wire forming. CAD with a sharp corner at 1/2 in is a crack, not a bend.
The rest of 4–14 mm
3/8, 7/16, and 1/2 are stock. Other diameters in 4–14 mm still form — they are not on the floor as production coil. 5.5 mm is the usual example: inside the band, not a standard size we run, tooling required. We will not silently swap it for 7/16.
Below 4 mm or above 14 mm: the page can still explain it; the quote will say no. Detail: heavy wire forming. Money and coil buy-in: quotes, tooling, and coil.
Tooling, programming, and coil
Non-stock wire in 4–14 mm is $2,500–$6,900 in tooling (2026 pricing). Setup is $175 per job. If we do not carry the steel for a single run, the client buys the coil — typically 1,500–2,500 lb depending on the supplier — and we run that material out.
Full terms: quotes, tooling, and coil.