Wire Manufacturing Services

Wire manufacturing services draw, coil, roll, spool, finish and heat-treat wire and raw wire stock. They also perform secondary services such as braiding, bonding, cabling, cutting, insulating, printing, slitting, straightening, weaving, and wire wrapping. Drawing is the process of pulling metal through a die or series of dies to reduce its diameter to a specified size. Rolling processes are also used to reduce the stock’s cross-sectional area. Wire manufacturing services perform several heat treating processes. Annealing reduces hardness, improves machinability, facilitates cold-working, and modifies a metal’s microstructure. Tempering reheats quench-hardened or normalized ferrous alloys to a temperature below the transformation range in order to decrease hardness and/or increase toughness. Patenting consists of passing wire through tubes in a furnace at approximately 970° C. In terms of secondary processes, some wire manufacturing services specialize in braiding, which forms a woven mesh of wires around the outside of one or more conductive cables and provides shielding against electromagnetic interference (EMI), radio frequency interference (RFI). Bonding is the process of connecting wires from package leads to a chip or bonding pads. Cabling is the twisting together or two or more insulated conductors to form a cable. Wire forming services shape wire into shelving, grids, guards or baskets. Wire wrapping services apply tape over insulated or uninsulated wires.

Wire manufacturing services form wire with flat, oval, and rounded profiles from a variety of materials. Aluminum is a malleable, ductile metallic element with good electrical and thermal conductivity, high reflectivity, and resistance to oxidation. Brass provides good strength, excellent high-temperature ductility, good bearing properties, and low magnetic permeability. Copper is ductile, malleable, and one of the best conductors of heat and electricity. Bronze, an alloy of copper and tin, is another commonly used material. Some wire manufacturing services form wire from low carbon steel, high carbon steel, stainless steel, iron, or molybdenum. Other companies provide products made from nickel alloys, precious metals, titanium, tungsten, or zinc. Proprietary wire materials include Hastelloy^®, a registered trademark of Haynes International, Inc., as well as Inconel^® and Monel^® , registered trademarks of Special Metals Corporation. 

Wire manufacturing services are located across the United States and around the world. They serve the automotive, aerospace and machining industries, and provide many different products. For example, wire for electrical and electronics applications is designed to carry current. Magnet wire is made of copper or aluminum and prevents continuity between adjacent turns in a winding. Medical wire is used in suture needles, dental products, spinal styles, and biopsy forceps. Music wire is made of high-carbon steel alloys and used in instruments such as guitars. Rope wire is used in the fabrication of yacht rigging and aircraft control cables. Spring wire is hard-drawn and available in diameters ranging from .031 in. to .500 in. Weaving wire is used to weave or braid cables. Welding wire is used in gas welding and brazing processes, as well as arc-welding processes in which the electrode does not furnish the filler material. Wire for electrical discharge machining (EDM) is specially coated. General-purpose machining wire includes wire types 303 and 416.

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