Wire Forming & Custom Spring Solutions in China

ChinaCustomStamping has established itself as a premier manufacturer of precision wire forming and custom springs in China’s competitive manufacturing landscape. With over 20 years of specialized experience, we combine German engineering precision with China’s manufacturing efficiency to deliver exceptional quality components at competitive prices. Our ISO 9001:2015 certified facility houses state-of-the-art CNC equipment capable of producing complex wire forms and springs with tolerances as tight as ±0.005 inches (±0.127mm).

What truly sets us apart is our commitment to providing complete manufacturing solutions – from initial design consultation through final delivery. We serve a global clientele across automotive, medical, electronics, and industrial sectors, with 80% of our production destined for international markets. Our integrated approach ensures consistent quality control at every production stage while maintaining lead times as short as 7 working days for standard orders.

What is Wire Forming

Wire forming and bending are essential manufacturing processes used to shape metal wire into precise configurations for various industrial, commercial, and consumer applications. These processes involve manipulating wire—typically made from steel, aluminum, copper, or other metals—into desired forms using specialized machinery and techniques. Wire-formed components are found in countless products, from automotive and aerospace systems to medical devices and household items.

It is a process of transforming straight wire into complex shapes through bending, cutting, coiling, and other techniques. Wire bending, a subset of wire forming, specifically focuses on creating angles, curves, and loops in the wire. These processes can be performed manually, with hand tools, or using advanced CNC (Computer Numerical Control) machines for high precision and repeatability.

The Wire Forming Process: Step-by-Step

1. Design & Material Selection
   • Computer-Aided Design (CAD) specifies wire type, diameter, and gauge. Stainless steel or steel is chosen for strength; aluminum or copper suits lightweight needs.
2. Straightening & Stretching
   • Coiled wires are fed through rollers to remove deformities. Care is taken to avoid over-stretching, which can cause necking (thinning and weakening the wire).
3. Shaping Through Applied Force
   • Automated machines (e.g., CNC, hydraulic) or manual tools bend, twist, or cut the wire. Techniques include:
     • Bending: Precisely forming angles or smooth curves in wire using mechanical force, typically through manual tools or automated CNC machines for consistent repeatability.
     • Swaging: Reducing wire diameter or creating tapered shapes by compressing the material through dies, often used to form smooth transitions or prepare wire ends for assembly.
     • Extrusion: Forcing wire through shaped dies to maintain exact cross-sectional dimensions along its entire length, ensuring uniform thickness and specialized profile requirements.
     • Stamping/Twisting: Combining cutting/pressing operations with rotational forming to produce intricate patterns or interwoven multi-wire configurations for enhanced structural properties.
4. Finishing
   • Surfaces are polished, coated, or plated to enhance functionality. Processes like electro-polishing (removing surface layers for smoothness) or zinc plating (anti-corrosion) are applied based on the end use.
5. Quality Assurance & Packaging
   • Rigorous checks ensure compliance with industry standards, especially in critical sectors like healthcare. Sterilization, precise packaging, and tamper-proof sealing protect products during transit.

Wire Forming Methods

• CNC Wire Bending: Computer-controlled precision for prototypes or low-volume batches.
• Four-Slide Forming: High-speed, multi-tool stamping for mass production.
• Roll Forming: Cost-effective for creating threads, grooves, or hardened components.
• Coil Winding: Producing electrical components by wrapping wire around a core.
• Hydraulic/Pneumatic Systems: Automated shaping for consistent, high-volume output.

ChinaCustomStamping specializes in two primary processing methods: CNC Wire Forming and stamping die bending. As you may know, we are experts in stamping die production. However, our other key strength lies in CNC Wire Forming, where we have over 20 years of extensive experience.

With our deep expertise, we aim to provide customers with cost-effective and optimized production solutions for any new wire forming project. Whether it’s precision bending, complex geometries, or high-volume production, our team ensures high-quality results at competitive prices. Trust ChinaCustomStamping for reliable and professional wire forming solutions tailored to your needs.

Material Options for Wire Forming

ChinaCustomStamping maintain an extensive inventory of premium materials to meet diverse application requirements:

Stainless Steels:

• 302/304/316 – Austenitic grades for superior corrosion resistance in medical, marine, and food-grade applications.
• 17-7 PH – Precipitation-hardening stainless steel for high strength and fatigue resistance in aerospace components.
• 410/420 – Martensitic grades offering excellent wear resistance for cutting tools and industrial blades.

Spring Steels:

• Music wire (ASTM A228) – High-carbon steel with exceptional tensile strength for precision springs.
• Oil-tempered wire (ASTM A229) – Ideal for heavy-duty springs requiring durability and shock absorption.
• Chrome silicon (ASTM A401) – Heat-resistant alloy for high-stress applications like valve springs.
• Chrome vanadium (ASTM A231) – Superior fatigue resistance for automotive and machinery springs.

Copper Alloys:

• Beryllium copper (C17200) – High strength & conductivity, used in electrical contacts and connectors.
• Phosphor bronze (C51000) – Excellent elasticity and corrosion resistance for marine hardware.
• Brass (C26000) – Machinability and aesthetic appeal for decorative and mechanical parts.

Specialty Alloys:

• Inconel 600/718 – Nickel-chromium superalloys for extreme heat and chemical resistance (jet engines, nuclear reactors).
• Monel (400/500) – Nickel-copper alloy with outstanding seawater corrosion resistance.
• Titanium (Grade 1-5) – Biocompatible and lightweight, perfect for medical implants and aerospace.
• Nitinol – Shape memory alloy for medical stents and actuators requiring thermal responsiveness.

Wire Forming Technical Capabilities

Our production facilities boast impressive specifications:

• Diameter Range: 0.1mm – 20mm
• Length Capacity: 1.5″ to 12 feet
• Tolerance Standards: ±0.005″ standard (±0.001″ achievable)
• Production Speed: Up to 1,200 parts/minute
• Bend Complexity: Up to 15 bends per component
• Surface Finish: Ra 0.2μm to 3.2μm

Quality Assurance & Testing

We maintain rigorous quality control measures throughout production:

In-House Testing Laboratory:

• Metallurgical analysis (1000X magnification)
• Salt spray testing (ASTM B117)
• Mechanical testing (tensile, torsion, fatigue)
• Hardness testing (Rockwell, Vickers, Brinell)
• Dimensional verification (optical comparators, CMM)

Quality Certifications:

• ISO certified
• SGS audited facility
• ROHS/REACH compliant materials
• ITAR registered (for defense applications)

Process Controls:

• Statistical process control (SPC)
• Gauge repeatability and reproducibility (GR&R)
• Process capability studies (Cp/Cpk)
• First article inspection reports (FAIR)

Wire Forming Applications

Our precision wire forms and springs serve critical functions across multiple industries:

Automotive:

• Fuel injection components
• Seat belt mechanisms
• Transmission system parts
• Electrical connectors

Medical Devices:

• Surgical instruments
• Orthodontic archwires
• Implantable components
• Diagnostic equipment

Electronics:

• Connector pins
• Relay contacts
• Battery contacts
• EMI shielding elements

Industrial Equipment:

• Agricultural machinery
• Conveyor systems
• Heavy machinery
• Valve components

Consumer Products:

• Appliance mechanisms
• Furniture hardware
• Sporting goods
• Electronic enclosures

Value-Added Services

We offer comprehensive secondary services to provide complete solutions:

Surface Treatments:

• Electroplating (zinc, nickel, chrome)
• Electroless nickel plating
• Passivation and chromate conversion
• Powder coating (various colors/textures)
• Electropolishing (medical grade)

Heat Treatments:

• Stress relieving
• Tempering
• Annealing
• Hardening and case hardening

Additional Processing:

• Precision machining
• Welding (resistance, laser, TIG)
• Assembly and packaging
• Laser marking and engraving

Relative products

Wire forming and bending are widely used,such production method can easily to make following items too

• Compression spring
• Torsion spring
• Extension spring

Our Competitive Advantages

Engineering Expertise:

• Dedicated R&D team with 20+ years experience
• Free DFM (Design for Manufacturability) analysis
• Prototype development in 3-5 days
• Tolerance optimization consulting

Manufacturing Capabilities:

• 50+ CNC machines in operation
• 15,000 sqm production facility
• 1M+ monthly production capacity
• Vertical integration for quality control

Customer Service:

• 24-hour quotation response
• Dedicated project managers
• English-speaking engineering support
• Transparent communication

Global Logistics:

• EXW, FOB, CIF terms available
• Licensed hazardous material shipping
• Customs documentation support
• Just-in-time delivery programs