Custom Wire Technologies (CWT) has refined a specialized wire forming process that feeds wire directly from a spool into a CNC (computer numerical control) machine, enabling rapid production with competitive pricing. Serving as a trusted partner to OEMs and researchers in the medical device sector, CWT leverages over 20 years of expertise to craft high-quality, custom wire forms using materials like medical-grade stainless steel and nitinol.
Despite not offering off-the-shelf wire forms, CWT stocks an extensive inventory of raw wire to provide customers with fast turnaround times. Jim Boldig, Director of Sales and Engineering at CWT, explains that setting up wire forming machines from large wire spools enhances efficiency by reducing the need for frequent operator adjustments, thus saving customers both time and cost.
“This is related to machine setup and efficiency,” declares Boldig. “When setting up a machine to run from a spool, we can put a large quantity (20-30 lbs) of raw material onto the payoff (the piece of equipment to hold and help feed material into the machine). The large quantity allows us to keep running with less operator interaction. Less operator interaction and setup are cost-savings for our customers.” According to Boldig, automation is essential. “Our forming equipment is capable of running unattended,” he clarifies. “With the right geometry, the machines can run over one or two hundred pieces per hour.”
Comprehensive Wire Forming for Versatile Applications
Custom wire forming at CWT is performed using a diverse array of metals and alloys, available in fine or microfine wire options. These custom wires can serve as individual medical device components or be assembled with other parts such as clips, rings, or links to create complex devices. In addition to high-volume CNC wire forming, CWT utilizes hand jigs, fixtures, and presses for complex shapes, ensuring versatility and precision in every piece.
Per Boldig, CNC wire forming machines excel at handling ultra-fine wires. “Our current capability with automation is as small as 0.05mm. This size is generally restricted to specific applications like radiopaque marker coils. However, when stepping up in size, like 0.4mm OD for example, we can get extremely competitive with a variety of forming geometries. Our equipment can run up to 0.8mm OD with stock tooling. We have created custom tooling to allow larger sizes like 1.6mm OD. If the customer believes the opportunity is worth the upfront resources, CWT will invest to make it a reality.”
Design Flexibility and Customization
Boldig emphasizes CWT’s adaptability to customer requirements—a standout strength that helps the manufacturer achieve precise results. “This ability increases our portfolio of capabilities all under the same roof. We often find ourselves performing manual operations to satisfy our customer’s requirements. Occasionally, we are using a piece of equipment to perform one step and then a separate manual operation to finish it. The specifics are in the details of the parts. Some details require an operator to see what is happening and assess the quality. We will use our engineering resources to solve a problem. If it cannot be run on a machine that does not mean it cannot be made.”
CWT’s comprehensive approach makes it a valuable resource for clients worldwide, spanning industries such as medical device manufacturing, dental surgery, and instrumentation design. The company’s capabilities extend beyond wire forming, offering processes like coiling, cutting, heat treating, grinding, welding, and more. The only step outsourced is raw wire drawing, which CWT sources through a network of trusted suppliers.
Choosing Between Stainless Steel and Nitinol
Boldig explains that nitinol, a nickel-titanium alloy known for its “shape memory” properties, can alter its shape in response to temperature changes. “Shape setting nitinol has allowed more diverse offerings of products to the industry. Customers develop parallel paths between stainless steel and nitinol to determine which will be the best for their application. Testing them together helps identify a front runner at a quicker pace.”
Boldig points out the key difference that influences price. “From a forming capability, stainless steel is usually the more economical alternative due to its ability to be formed at the machine level, as nitinol requires fixtures and heat treatment, which relates to higher part costs,”
“Each material has their advantages and disadvantages, and the customer will ultimately determine what is best for their project,” Boldig states. “We work with our customers to produce processes that work. The end goal is to find efficient and economical solutions.”
Partner with CWT for Custom Wire Solutions
With an unwavering commitment to quality and efficiency, Custom Wire Technologies supports a broad range of wire forming and finishing services for the medical device industry. Whether you’re developing prototypes or scaling up for mass production, CWT is ready to partner with you in finding effective, cost-efficient solutions.
LET’S CONNECT!
If you’re interested in learning more about all the medical device component capabilities at Custom Wire Technologies, please reach out today. We’re excited to learn how we can serve you and help your business thrive!