Wire fabrication plays a pivotal role in the manufacturing industry. This process involves transforming wire into distinct shapes and forms to craft functional and decorative products. Wire fabrication offers various possibilities for industrial and commercial applications, from wire mesh and baskets to wire racks and shelving. However, selecting the right fabrication method is critical for ensuring the success of a manufacturing project.

Proper planning for wire display fabrication is essential to ensure the final product’s quality, longevity, and successful operation. Therefore, it is important to make informed decisions regarding wire fabrication.

What We’ll Cover:

Considerations for Choosing the Right Wire Fabrication

Choosing the right wire fabrication for your manufacturing project involves several key considerations, including wire forming methods, materials, and properties.

Wire forming methods are the techniques that shape and manipulate wire into various forms, like material handling carts. Different wire-forming techniques produce wires with distinct characteristics, such as superior strength and durability. Additionally, these methods can help increase production efficiency by reducing material waste. Here are five common wire-forming methods:

Manual Wire Forming

Manual wire forming involves using handheld tools or machines to shape the wire into the desired form.

This technique is most efficient for fabricating basic wire forms produced in low quantities.

Manual wire forming is also ideal for creating prototypes or testing wire designs.

Coil Wire Forming

Wire coils are usually produced using this process.

This technique perfectly suits creating wire forms like electrical coils.

CNC Wire Forming

CNC wire forming is an automated process where custom wire fabricators utilize CAD technologies to shape wire into a specific form.

This method ensures the best results for intricate wire forms that demand accuracy and uniformity. It is ideal for applications where precision is of utmost importance.

CNC wire forming can benefit those needing to produce many wire forms with minimal waste. It is ideal for mass production.

Hydraulic Wire Forming

The hydraulic motor provides the necessary power and control to form the wire into the required shape.

After a wire-forming process, the machines automatically eject the finished shapes.

Pneumatic Wire Forming

The straightening machine processes the wire giving it the shape desired and cutting it up to the correct length with a pneumatic method.

It boasts high accuracy and precision, preventing potential damage to the wire surface.

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Key Wire Properties

Wire properties are significant factors to consider when choosing the right wire display fabrication for your project. Understanding these properties helps you select the most suitable custom wire fabricators for your application.


Ductility refers to the ability of the wire to deform under stress without breaking. Highly ductile wires can get bent, twisted, or stretched into extremely thin wires without breaking.


Weldability measures how easily the material can get joined with different processes and welding techniques without compromising its structural integrity.


This refers to the ease with which the wire gets cut or shaped without wearing out tools. Wires with good machinability are easy to shape from sheet metal.

Tensile Strength

Wires with high tensile strength withstand greater stress or force, making them ideal for applications where strength and durability are critical.

Corrosion Resistance

Another essential property worth considering is the wire’s corrosion resistance. Wires with good corrosion resistance can withstand exposure to moisture, chemicals, and other elements.

Common Wire Forming Materials

Some common materials used by custom wire fabrication services include:


Aluminum’s popularity in manufacturing is increasing due to its lightweight and superior rust resistance compared to other wire-forming materials. It is commonly used for wire parts.

Carbon Steel

Carbon steel is ideal for wiring components as it offers custom wire fabricators durability and adaptability. However, it is more vulnerable to corrosion than aluminum. Thus, proper maintenance is a must.


Copper is a highly conductive and malleable material commonly used for electrical applications. Even under stress, its core strength remains unaltered and is not diminished.

Nickel Alloy

Nickel alloys are sought-after by several industries, particularly those that require high-performance components. Aerospace, medical, and automotive industries are among the sectors that hugely benefit from their strength, corrosion resistance, and heat resistance.

Stainless Steel

It is an iron alloy with a minimum of 10.5% chromium content. Stainless steel wire fabrication is highly sought-after for countless applications because of its advantages, like its flexibility and strength.

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Stainless Steel Categories

Some of the most common stainless steel categories include:

Austenitic Stainless Steel

This type of stainless steel is non-magnetic due to its high amounts of austenite. It is commonly used in applications where high levels of corrosion resistance are necessary, such as in chemical processing equipment, food processing equipment, and medical devices.

Martensitic Stainless Steel

Martensitic stainless steel contains higher levels of carbon and lower levels of nickel than austenitic stainless steel, making it less corrosion-resistant. This type of stainless steel is commonly used in applications where high strength and hardness are vital, such as in automotive and aerospace applications.

Ferritic Stainless Steel

This material has a magnetic property and is moderately resistant to corrosion. Ferritic stainless steel consists of a body-centered cubic crystal structure and comprises higher levels of chromium and lower levels of carbon. It commonly appears in water heating applications and kitchen equipment.

Duplex Stainless Steel

It has a two-phase microstructure consisting of both austenitic and ferritic phases. Duplex stainless steel offers a high level of corrosion resistance and high strength.

Key Takeaways

Wire forming methods like manual, coil, CNC, hydraulic, and pneumatic each have certain strengths and drawbacks. The most suitable option would largely depend on your project’s requirements. Ductility, weldability, machinability, tensile strength, and corrosion resistance are significant elements to consider.

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100% U.S.-Based Tube Fabrication

Above all, we’re here to be your greatest resource in contract manufacturing. We conduct all of our stainless steel wire fabrication in the heart of New England. Plus, we’re ready to ship anywhere in the U.S.!

Wirefab Inc. has over 65 years of experience in custom sheet metal fabrication as one of New England’s top custom welding service companies. Whether you need custom CNC machininglaser metal cutting, or material handling cartswe’re here to help. Above all, we’re always eager to solve our customers’ problems with a broad range of custom wire fabrication services. Contact us today to see how we can simplify your next project.

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