Understanding the Wire Forming Process: From Concept to Completion

KMK specializes in precise wire forming for a variety of fabrication needs, most often in combination with sheet metal and tube fabrication to create complex racks, carts, and other products. Today, we’re taking a deep dive into the wire forming process and the different steps that go into making quality products out of metal wire. 

The Process of Forming Wire

Wire forming is a fairly simple process at first glance. It involves straightening or bending metal wire into very particular shapes, like hooks, circles, and much more. However, like any other fabrication process, forming wire requires knowledge and an attention to detail to ensure that each bend is precise and the finished wire meets the needs of the end-use product.

The process of wire forming can be boiled down to a few steps. 

• Material Selection: Our customers will come to us with whichever type of wire that they want in terms of material and diameter. At KMK, we work with carbon steel wire in thicknesses ranging from 0.120 to 0.375 inches, and stainless steel wire with diameters up to 0.25 inch. Carbon steel is cost effective and good for high-strength applications, while stainless steel offers good all-around physical properties and exceptional corrosion resistance.

• Wire Straightening: Drawn wire is typically stored in coils, regardless of the material type and thickness, and needs to be straightened out before the actual forming can start. This step removes any deformities that may have formed while it was stored.

• Wire Forming: Once the wire is straightened, it can then be formed into its final shape. This involves using a machine to apply force to the wire and bend it at a precise angle, or into a particular shape. For higher precision, KMK uses CNC machines, which allow us better control and consistency with each product.

• Welding and Finishing: Depending on the actual project, this may not always be a necessary step, but at KMK, these are both regular services we provide in addition to forming wire. We have single-point spot welders to weld together formed wires and other metal pieces. Some applications are better suited to MIG or TIG welding, which we can also perform as needed.

Looking for a partner in fabrication?

As we’ve mentioned, wire forming is often just one step in the fabrication process at KMK. We combine the metal wire parts with fabricated metal sheets and tubes in order to create a variety of different products, all under one roof. If you’re interested in our capabilities, head over to our website to learn more about how KMK can serve you and request a quote!