Shaped Wire Case Study

Whether its round, square or we need to create a specially shaped wire for your part, we have the experience to think outside of the box to take you where you want to get.

When our customer came to us with his original design, the consensus of the engineering team was that the part they designed, while likely functional and meeting all of their needs, wasn’t manufacturable as designed.

Since we had prior experience feeding discreet wire pins with spherical ends into the fourslide machine and welding them to the stamped and formed piece made from strip stock in the fourslide die section, the customer was not receptive to a two-piece construction.

Thinking outside the box, our engineering team proposed using round wire to create both pin body and flattened portion for crimping, while incorporating a milling head on the fourslide machine to produce these offset, crimpable, round wire pins that will plug in to the female power supply cord. Beginning with the round wire, these parts are completely produced, one per machine cycle, at high speeds on the fourslide machine.

An electrical connector customer needed a retaining ring that had to have both a constant size ID, and a tapered OD. Screw machine options were not applicable if the spring characteristics needed were to be accomplished. Stamped, coined, trimmed and formed options were all too costly for the market they wanted to penetrate. Our engineering team worked with a wire supplier to supply GEMCO with a shaped wire that could be wrapped into a ring and have all of the ID-OD parameters met, as well as being able to be heat treated and gain spring characteristics during assembly and in application.

Not round wire, not square wire, but rather a specially designed shaped wire unique to a specific component.

You can trust GEMCO to help you with manufacturable and functional component design – you know what you need, we know how to make it!