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Wire Form Technical Design Resources

The section below gives some technical advice on wire forms such as: How to dimension your wire form, the radius of a wire for, and what ranges of wire diameter can be formed.

 

Custom Wire Form Design

We help OEM engineers with their wire forms.

At Master Spring, we’ve been manufacturing custom wire forms for OEMs for more than 70 years. Learn more about how we can design and manufacture your wire forms for your next application by calling us at 708-453-2570 today.

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Custom Wire Form

Wire Form Dimensions

The diagram and notes describe how to specify dimensions for wire forms. We have shown our preferred ways to specify dimensions to make it easier to inspect and produce your part.

Please refer to the legend below in regards to the wire form dimensions diagram:

  1. Bend segment drawn from edge of cut-off to theoretical corner of outside edges.
  2. Bend segment drawn from inside theoretical corner to inside edge of perpendicular bend.
  3. Bend segment drawn from inside edge of perpendicular bend to inside theoretical corner of inside edges.
  4. Inside angle.
  5. Inside diameter.
  6. Length from edge of cut-off to center of inside diameter.
  7. Bend radius drawn to the inside edge of the bend.
  8. Wire Diameter.

 

Wire Form Tolerance Note on F Dimension:

The accumulated variation of the overall length (F) will be larger than the variation of any one dimension that makes up that overall length. A dimension like (F) that is made up of a series of bends and feed segments should be a referenced dimension. If a tolerance on an overall dimension is required, it will have to be determined after a production run.

 

General Rules of Thumb: Smallest Radius Bends (Dimension G)

  1. For low carbon (low tensile steel), we will use a bending pin with a diameter that equals 1.5X the wire diameter. So the inside radius of the bend will equal 0.75X the wire diameter.
  2. For harder spring tempered steel, we will use a bending pin with a diameter that equals 2X the wire diameter. So the inside radius of the bend will equal 1X the wire diameter.

 

Wire Diameter

We have a wide range of CNC wire forming machines that can manufacture custom wire forms with diameters as small as 0.010″ or as large as 0.500″ (0.25mm to 12.7mm) and any size wire in between.

 

Wire Form Material Type

We manufacture custom wire forms from all types of material. The most common material types for wire forms are cold rolled steel (1008 or 1010 basic wire), stainless steel (type 302, type 304, type 316 or type 17-7 PH), music wire, hard drawn and oil tempered. You can learn about the suitable uses of each material type in our Properties of Materials chart.

 

Wire Form Dimensions Drawing:

Wire Form Dimension Diagram

Wire Diameter

Specializing in building long-term partnerships with OEMs, Master Spring & Wire Form Co. has the expertise and latest equipment to manufacture the difficult or “impossible to make” wire forms. We have a wide range of CNC wire forming machines that can manufacture custom wire forms with diameters as small as 0.010″ or as large as 0.500″ (0.25mm to 12.7mm) and any size wire in between.

Wire Form Material Type

We manufacture custom wire forms from all types of material. The most common material types for wire forms are cold rolled steel (1008 or 1010 basic wire), stainless steel (type 302, type 304, type 316 or type 17-7 PH), music wire, hard drawn and oil tempered. You can learn about the suitable uses of each material type in our Properties of Materials chart.

Common Extension Spring Materials Include:

  • High Carbon Spring Wire
  • Carbon and Alloy Wire
  • Hard Drawn Wire
  • Alloy Steel Wire
  • Stainless Steel Wire
  • Non-ferrous Alloy Wire
  • And Many More!
Types of Wire Form Material” width=

Wire Forms Video Gallery

Master Spring not only has the ability to manufacture custom wire forms to virtually any shape or size, we also proudly offer a number of secondary operations and finishing services, like threading, chamfering, tapping, welding, plating and passivating.

Whether you need a wire form with a diameter of .010″ or 0.500”, you’ll find the partner you’ve been searching for in Master Spring. We specialize in supplying OEMs their requirements of medium to high quantities of wire forms. If you are an OEM searching for a world-class supplier of your wire forms, let us know about your needs.

Watch the videos to see our custom wire form capabilities.

A Wire Forming Success Story

Custom Spring Clips for Electronics

An integral part to the functioning of an OEM’s heat sink, this wire form design is a great example of how repeatable production and inspection processes result in near zero defects.

READ MORE

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    1340 Ardmore Ave., Itasca, IL 60143

    Phone: 708.453.2570 | Fax: 708-453-6420