What is a wire spring?
When it comes to springs, you usually think of spiral or coiled shapes. The wire form does not have coils or springs, but is essentially a section of wire bent into a specific shape and angle. The uses of metal wire form are endless, and manufacturing metal wire form is a professional operation that requires unique design skills and engineering technology. Although wires are a unique component, they are related to our spring manufacturing capabilities and knowledge, and share similarities in the design of tension, compression, and torsion springs. We translate this expertise into designing and manufacturing shapes and sizes to meet the most demanding applications.

The wire form is used in almost all industries and applications. The most well-known forms of wire include hangers, springs, and pins, but other forms of wire can be used as light bulb filaments, electrical contacts, etc.
One of the most common large-scale wire applications is wire handles. The handle can be manufactured with wire sizes of 200000 or more, designed to slide into holes at both ends, and has a molded handle above for easy portability.
One of the most common applications of wire forms is battery contacts, as they are a fast and inexpensive component. The battery contacts are designed as spiral springs with supporting legs, which can be welded to the base later. Some battery contacts are designed as wire springs, while others are designed as stamped parts made of thin plates or strips. Usually, this type of application requires nickel material as a coating or substrate.
The lighting industry is one of the common industries that uses CNC wire forming because it is durable and can meet strict tolerances. Lamp wire is a common simple wire form designed to securely fix lamps to ceilings.
You may not know, but wire forms can be used for some of the most common household items, such as mousetraps. The simple front of the mouse trap is a good example of a common wire form. The safety pin also uses a similar design, but when used on a large scale, its basic shape will transform into a large industrial or agricultural machinery. Usually, larger wire forms are used to connect tractors and other items to another device.

There are various uses for wire forms, with different bending configurations depending on the application. The wire form can be designed to provide force in applications that require deflection or torsion forces using high carbon spring steel, or in applications that require support or structures using low carbon steel. Typical designs of wire forms include connecting rods, torsion bars/rods, and wires. A connecting rod is a product that requires two or more details to connect and work together to manage force and motion. A torsion bar is a form of wire that provides torsional force when one or both ends rotate along the length of the component.

In terms of manufacturing, the most common method for wire forming is to use automatic presses and manual bending equipment. At Heli Spring, we simplify your spring purchasing experience by providing you with accurate design input while meeting your requirements for quality, price, and delivery. This is achieved through the use of our customized Customer Order Management System (COMS) software, our spring design software, and professional spring manufacturing equipment.

Wire Forming Process
The efficiency of manual wire forming process decreases, and manufacturers choose to use automated machines to increase production. These machines can produce large-scale wire through various mechanical processing stages.
Machines can shorten delivery times, reduce costs, and produce complex wires. But first, developing wire specifications is crucial for the multifunctionality of the project. You must also choose suitable materials and machines to provide high-quality results faster.
Simply put, this process involves basic stages including wire selection, wire straightening, force application, and secondary processing. Here is a step-by-step guide for the process:
Wire selection
The initial CAD design determined the wire type, diameter, and specifications. Stainless steel and steel are typical wire types that require durable and elastic components.
On the other hand, lightweight wires such as copper and aluminum can meet applications with lower requirements. Various alloy materials such as brass, copper, and carbon steel can also meet different wire forming applications.
Wire straightening and stretching
Due to the fact that manufacturers store wires in coil form, it is necessary to stretch and straighten the wires before processing. The straightening process can eliminate the stress and deformation accumulated by wires in the storage room.
Reaction force helps to thin and stretch the wire, but it should be avoided to elongate the wire. In addition, excessive stretching can cause necking, hindering the final design and weakening the wire structure.
Apply force
Force must be applied to change the shape and contour of the wire into the desired wire forming shape. Force will generate designs with a series of configurations.
You can manually apply force or use various machines such as molds and cutting equipment. The four slider and CNC wire forming machine are suitable for large-scale industrial production.
Applying force includes twisting, stamping, bending, forging, squeezing, and upsetting. Anyway, upsetting involves deforming the wire by compressing it axially to improve its shape.
Squeezing is the process of passing a wire through a narrow area to confirm its uniformity, while forging involves using appropriate tools to deform it at the appropriate axial angle and shaping it through a bracket.
Meanwhile, bending involves shaping wires into specific angles, while stamping involves using special equipment to bend specific components. Finally, twisting allows you to combine multiple wires into a suitable shape.
fine machining
The final product type and application environment determine the quality of precision machining. Some applications, designs, and wires may not require precision machining. But you may need forging, embossing, upsetting, slotting, and cutting to perfect the product.
Overall, you must properly remove and adjust sharp and burr edges. Surface treatment can enhance the shape of wire, giving it new functions and characteristics suitable for application. For example, electropolishing can remove the top layer and leave an ultra clean surface.
Electropolishing can improve durability and reduce friction of finished wires. Other secondary finishing processes include galvanizing, passivation, vinyl, nickel, and powder coating.
Quality Assurance and Packaging
The application of high-quality wire forming in industries such as healthcare follows strict rules to promote the safety of nursing staff and patients. Therefore, manufacturers must provide quality assurance for precision machining processes such as sterilization.
The most important thing is that proper packaging can extend the shelf life and reduce manual opening during use. This process may require high-quality boxes, bundled packaging, and packaging buckles.

Stainless steel wire forming is commonly used for:
• High flexibility and extensibility
• Durability
• Superior tensile strength
• High temperature resistance
• Corrosion resistance
• Washable or passivated
• Durable and long-lasting
• Widely applicable

When components are to be used in harsh environments, exposed to high temperatures, humidity, and chemicals, stainless steel wire forming is usually chosen. Industries such as food processing, medical equipment, medical devices, agriculture, industrial control, automotive, lighting, and aerospace typically use stainless steel because reliability and long-term functionality are crucial.