Master Spring custom manufactures complex, custom wire forms from round wire, including retainer clips, fish clips, battery contacts, handles and more.
Industry: Hardware and Fasteners; Residential Pumps
Application: The handle is attached to a submersible sewage pump used in residential applications. We also make smaller handles for sump pumps.
Material: 0.250” stainless steel 302 wire
Special Features: Packed 250 pieces per box
Chill Coil
Part Names: Sand mold cooling coil, casting chill coil
Industry: Hardware and fasteners: Metal casting
Application: The cooling coil or chill coil is placed in the sand mold to produce local chilling and equalize the rate of solidification throughout the casting
Material: 0.162” C1008 bright basic wire
Special Features: Copper coated
Electrical Contact Spring
Part Names: Battery terminal spring contact, gold plated stainless steel electrical contact, coil spring contact
Industry: Electronics
Application: Coil spring battery contact in medical diagnostic equipment
Part Names: Stainless steel wire clip, filter hairpin clip
Industry: Diesel Exhaust Fluid (DEF)/Urea sensing solutions and DEF/Urea delivery modules for automotive, on-highway truck and off-highway applications
Application: Hairpin clip for filter in heater module of Temperature Ultrasonic Level and Concentration (TULC) sensor for SCR Diesel Exhaust Fluid (DEF) tanks
Material: 0.041” stainless steel 302 wire
Special Features: Clean cut and free of oil
Bait Snap
Part Names: Fishing stainless steel snap, bait snap, wire form bait snap, spring snap
Industry: Fishing tackle
Application: Snaps give the angler a quick and easy way to change lures and rigs
Material: 0.047” stainless steel 302 wire
Special Features: Vibratory deburr to remove sharp edges at cutoff
Application: One end of the corkscrew wire form screws into the end of soft bait, and the other end is assembled to the looped-end of the fish hook
Material: 0.040” stainless steel 302 wire
Special Features: Right-hand wound
Link Hook
Part Names: Galvanized steel link hook, fusible link hook, wire hook
Industry: Hardware and fasteners: Fire protection equipment
Application: The wire hook is a fusible link component used in mainstream range hood fire protection systems for both domestic and commercial applications.
Special Features: Eyelet has a small coil index (ratio of mean coil diameter to wire diameter). Eyelet must maintain full radius near cutoff with a gap.
Lock Spring
Part Names: Medical device lock spring, needle cartridge spring, stainless steel lock spring
Industry: Hardware and fasteners: Micro needling device used in dermatology
Application: Lock spring is used to lock sterile needle cartridge to handpiece base
Material: 0.020” stainless steel 302 wire
Special Features: Packed 1,000 parts per labeled, double bag
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Inspection Display Stand
Part Names: Aluminum wire stand, portable display stand
Industry: Hardware and fasteners: Portable ultrasonic flaw detectors for locating and sizing of hidden cracks, voids, disbands, and similar discontinuities in welds, forgings, turbines and other structural components
Applicatoin: Aluminum wire form stand provides convenient, lightweight support to keep portable inspection display upright
Material: 0.250” aluminum wire 6061 T6
Special Features: Chamfer ends, mill flat ends, drill hole in each end and tap, chromate conversion coat, and black plastisol dip coat
Spring Clip
Part Names: Heat sink clips, PCB spring clips, wire form clips
Industry: Electronics
Application: Spring clip quickly and securely mounts heat sinks to a wide range of electronics packages, including: BGA, QFP, LCC, LGA, CLCC, TSOP, DIPs and LQFP components without needing to drill holes in the PCB
Material: 0.033” stainless steel 302 wire
Special Features: Individually packed in heat sealed bags and labeled
Antenna
Part Names: Brass coil antenna, transmitter antenna, water meter antenna
Industry: Electronics
Application: Antenna for transmitter on water meter
Material: 0.032” brass spring tempered wire
Special : Coiled with variable pitch
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Precision Wire Forming Capabilities
As the industry’s leading custom wire form manufacturer, we are your one-stop source for precision wire forming for complex bends in a wide range of wire sizes. Learn about our extensive production services—from threading, chamfering and swaging to rapid prototyping, special packaging, assembly services and more.
MACHINING AND PRESS CAPABILITIES
Master Spring manufactures custom wire forms with chamfered, threaded or flattened ends. Using robotic technology, we form special ends in-line to streamline operations.
Wire Form with Chamfered Ends
Wire Form with Flattened Ends and a Punched Hole
Wire Form with Chamfered Ends and Drilled Hole
Formed Parts with Chamfered Ends
Wire Form with Notch
Wire Form with Swage (Press) Feature
Wire Form with Swage on One Side
Black Wire Form with Turned Down Chamfer thread
ENGINEERING SUPPORT
Need help creating a new design or solving a problem with your existing wire form? Our engineers, machine setup technicians, and tool makers review your wire form for functionality and manufacturability and look for improvements and cost savings. With over 75 years of custom wire form manufacturing experience, we solve the toughest challenges.
Contact us if you need samples quickly or to setup a discussion with a knowledgeable engineer to review and advise on your design.
Master Spring tailors wire form packaging to meet your unique assembly line and finished product needs. Our custom packaging solutions include tangle-free packing for efficient assembly operations, individually bagged and labeled parts ready to ship to your customers, and custom-built crates that securely transport large, heavy wire forms. Contact us today for more information about our wire forming special packaging services.
Let Master Spring’s wire form assembly services lower your production costs by reducing the components you must purchase and inventory. We can assemble your wire form with its mating part and send the sub-assembly to you.
As your trusted wire form manufacturer, Master Spring’s experience and quality process provide the documentation you require for your wire forms.
We have experience providing a Production Part Approval Process (PPAP) to our customers. After receiving our PPAP report, you can assess our process stability, review our controls to provide conforming product and have an approval outlet for any wire form design changes.
We create a First Article Inspection Report (FAIR) for each production run. The FAIR indicates the nominal dimensions, tolerances, precise measurements and methods of measurement for a requested quantity. Each FAIR provides a record of the raw material heat number to provide traceability to the batch of wire used for each production run.
Upon request, we can include certificates of compliance, material certificates and finishing certifications with each shipment of wire forms.
Strict vendor management and lot control enable us to comply with regulatory compliances including Conflict Minerals, DFARS, REACH, RoHS or California Prop 65. Let us know your documentation, certificate and compliance requirements when you request a quote.
WIRE DIAMETER RANGE
Our 3D-bending machines form a wide range of wire sizes. With full CNC control of all axes, our machines can manufacture complex, custom wire forms with wire diameters as small as 0.010” or as large as 0.394” (0.25mm to 10mm), and any size in between. We have invested in a large inventory of universal tooling to cover the wire diameter range for each wire forming machine. If your wire form requires custom tooling, our in-house tooling design and machining capability supplies custom tools quickly and economically.
WIRE MATERIAL TYPES
Master Spring maintains strong relationships with local, qualified wire distributors and mills that offer quality wire to meet your specifications. We have years of experience making custom wire forms from many different material types:
Low-carbon Steel Wire Grades: 1006, 1008, 1010, 1018 and 1020
Medium-carbon Steel Wire Grades: 1035, 1038 and 1045
High-carbon Spring Steel Wire : Hard-drawn wire, music wire and oil-tempered
*We normally use a Bright Basic surface quality for the low- and medium-carbon steels. Some Carbon Wire Types can be pre-plated with a galvanized, zinc-coated finish, a tin-coated finish or Bezinal®-coated finish.
Properties of Materials Guide
Looking for information about common materials used in precision wire forms? Explore our guide to learn about nominal chemistry, minimum tensile strength, maximum operating temperatures, Rockwell hardness and suitable uses for each material.
To complete your precision wire form, we offer an extensive variety of finishing types. We manage a strong network of local, qualified vendors who offer quality finishes, short lead times and competitive pricing. Learn more about our finishing services below.
In-house Stress Relief
We use in-line ovens at each wire forming machine to apply low-temperature stress relief. This process alleviates residual stresses produced by prior cold forming and improves the wire form’s shape memory to maintain its formed shape.
Heat Treatment
For wire forms that require high-temperature hardening, such as austemper, harden and temper, vacuum heat treatment and ferritic nitrocarburize, we partner with local, qualified heat-treatment companies.
Shot Peen
Shot peening improves resistance to fatigue, prevents cracking and increases lifecycle. The shot peening process blasts the surface of the wire with steel or glass pellets to create deformations. Our local, qualified vendors specialize in quality shot peening and surface preparation.
Tumble
Tumbling improves surface finish by removing unwanted sharp edges and burrs from standard machine cuts.
Plate
Our large network of qualified platers provides a wide range of plating finishes such as black oxide, zinc, nickel, tin, trivalent chromate and many more finishes in a variety of colors.
Powder Coat
Numerous powder coat colors are available for wire forms.
Passivate
An acid treatment for stainless steel, passivation removes contaminants and improves corrosion resistance. We recommend passivating stainless steel wire forms used in the medical and food industries.
Electropolish
Electropolish brightens, removes burrs and passivates. For best results, use it on 300-series stainless steel types.
In-house Dye or Paint
Color coding helps identify and distinguish similar parts in your assembly line. We use an environmentally safe, water-based polymer coating. This coating adheres to the wire form in-line immediately after oven stress-relief.
E-coat
E-coat is an electrically applied paint coating that is used as a decorative or protective finish. It enhances appearance while also protecting the surface of wire forms.
Magni Coat
Magni coat is a thin, paintable coat that provides exceptional corrosion protection in extreme environments. It is superior to zinc-plating.
Plastic Coat
We can add a plastic coating to your wire forms in a variety of available colors.
Pre-applied Inert Threadlocking
This pre-applied process fuses a nylon threadlocking patch to the external threads of wire forms. Once applied, the threads are self-locking, self-sealing, dry to the touch and ready for immediate use.
CUSTOMER SUCCESS STORY
Custom Threaded Belt Hooks for a Construction Power Tool
See how Master Spring’s skilled machine setup technicians automated numerous operations into one continuous production line to improve a wire form’s run rate with zero defects.
Packaging Solutions for Direct Shipments to Your Customers
Master Spring streamlined a manufacturer’s product packaging by supplying wire clips individually bagged and labeled to include in their circuit board heat sink kits.
Engineering assistance to overcome wire form design obstacles and offer you a solution
Skilled machine setup technicians who develop creative ways to manufacture complex wire forms without additional operations
In-house, experienced tool makers who design and manufacture custom tools and gauges to match your wire form print and monitor production
STATE-OF-THE-ART MACHINES
Multi-axis, all-servo CNC wire forming machines with a wire range from 0.010” to 0.394”
Wire forming machines with laser sensors and touch probes to automatically monitor dimensions in-line
CNC milling machines to custom manufacture tooling and gauges
Robotic-fed machining units to turn down wire diameter, chamfer, thread, mill, swage, flatten and punch wire forms
Keyence instant measurement equipment that inspects multiple parts and wire form dimensions within seconds, reduces inspection time and saves hourly monitoring data
CURRENT TECHNOLOGY FOR INCREASED EFFICIENCY
JobBOSS ERP software to integrate quoting, job routing, purchase orders, shipping and invoicing
SOLIDWORKS CAD software for a collaborative design process
MasterCAM software to design and manufacture tooling and gauges
Dozuki video software to document and standardize work instructions for repeat setups
Contact Master Spring
Need a custom wire form or coil spring? We make it work. Fill out the contact form and a representative will respond within 1 business day. If you have a PDF or CAD file, you can submit to request a quote.
