Custom Wire Forms & Precision Wire Forming

Wire Management Clip

Part Names: Wire clip, cable management clip, stainless steel clip, stainless wire management clip

Industry: Solar photovoltaic (PV) mounting systems or solar power mounting solutions

Application: Wire form clip attaches to solar panel module frame and manages DC, AC, and communications cables within the array

Material: 0.090” stainless steel 302 wire

Special Features: Packed 20 pieces per bag

Workpiece Contact Probe

Part Names: Contact trip, precision point tip, contact tip, work contact element, nose piece, no-mar tip, workpiece contact probe

Industry: Construction power tools

Application: Workpiece contact probe presses against work surface to aim nail and allow nailing gun to fire

Material: 0.156” annealed C1065 cold-rolled steel

Special Features: Reduce wire diameter, chamfer both ends, thread, notch (press), austemper harden, black oxide finish

Battery Connector

Part Names: Coiled battery contact spring, nickel plated coil battery spring

Industry: Electronics

Application: Coil spring battery contact

Material: 0.028” phosphate-coated music wire

Special Features: Electroless nickel plate, packed on tack boards to prevent tangling

Retainer Clip

Part Names: Stainless steel clip, wire clip, stainless steel retainer clip

Industry: Filters for petroleum, industrial, agricultural, heavy-duty and biofuel markets

Application: Retainer clip used in vapor control cap on above ground farm tanks, fuel transfer tanks and oil tanks

Material: 0.058” stainless steel wire

Special Features: Layer-packed on cardboard sheets to minimize tangling

Wire Spring Latch

Part Names: Hold-down clamp, cover latch, wire form clip, retaining spring clip, filter latch, wire spring latch

Industry: Inlet filters, liquid separators, and vapor condensers for industrial vacuum pumps

Application: Wire form latch fastens top housing to bottom bucket

Material: 0.090” stainless steel 302 wire

Special Features: Two wire form pieces assembled in-line on wire forming machine to create latch

Trotline Clip

Part Names: Fishing trotline clip with brass swivel, stainless steel fishing clip and brass swivel assembly

Industry: Fishing tackle

Application: Clips snap on and off trotline fast and easy to increase fishing time in the water

Material: 0.067” stainless steel 302 wire

Special Features: Assemble brass swivel to stainless steel clip in-line at the wire forming machine

Cable Management Clip

Part Names: Wire formed clip, wire management clip, stainless steel clip, stainless cable management clip

Industry: Solar photovoltaic (PV) mounting systems or solar power mounting solutions

Application: Wire form clip attaches to solar panel module frame and manages DC, AC, and communications cables within the array

Material: 0.072” stainless steel 302 wire

Special Features: Packed 30 nested pieces per labeled box; part inspected by UL to maintain UL certification

Large Fishing Lure Body Wire Forms

Part Names: Stainless steel wire forms for lures, wire forms for muskie lure molds

Industry: Fishing tackle

Application: Wire forms are molded into fish lure body to provide harness to assemble hooks and to connect to line

Material: 0.047” stainless steel 302 wire and 0.067” stainless steel 302 wire

Special Features: Special packed to prevent tangling during shipping

Pump Handle

Part Names: Stainless steel handle, wire handle, sewage pump handle, sump pump handle

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: 0.400” 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

Material: 0.028 gold pre-plated stainless steel 302 wire

Special Features: Gold-plated wire; packed three stacks of five nested pieces per ziplocked bag

Wire Loop Handle

Part Names: Aluminum wire handle, wire loop strap fastener

Industry: Hardware and fasteners

Application: Wire loop handle used as a belt or strap fastener

Material: 0.125” aluminum ¼ hard wire

Special Features: Tumble or vibratory deburr to remove sharp edges

Spreader Bar and Spinnerbait Wire Form

Part Names: Spreader wire rig, wire spreader, spreader bar, R-bend spinnerbait form, spinner bait wire form

Industry: Fishing tackle

Application: Spreader bar allows you to fish two snells at once. Spinnerbait wire shafts fit in spinnerbait molds.

Material: 0.040” stainless steel 302 wire and 0.047” stainless steel 302 wire

Special Features: Special packed to prevent tangling during shipping

Handle

Part Names: Filter handle, wire handle, hydraulic filter handle

Industry: Hydraulic filters

Application: Handle for top of hydraulic filter

Material: 0.105” galvanized music wire

Special Features: Layer-packed on cardboard sheets to minimize tangling

Retainer Spring

Part names: LED retainer clip, lens retainer spring, galvanized wire retainer, downlight wire form retainer

Industry: Commercial lighting

Application: Lens access retainer spring in round LED variable beam downlight

Material: 0.051” galvanized music wire

Special Features: Assemble and heat shrink three black rubber sleeves on retainer clip

Optic Hold Spring

Part Names: Stainless steel optic hold spring, LED optic wire form

Industry: Commercial lighting

Application: Healthcare LED luminaire uses asymmetric focusing optic for illumination onto patient beds

Material: 0.031” stainless steel 302 wire

Special Features: Center loops are in-line and perpendicular to wire line

Retainer Clip

Part Names: Stainless steel retainer clip, MR16 LED wire form clip

Industry: Commercial lighting

Application: Retainer clip for MR16 LED exit and emergency lamps

Material: 0.041” stainless steel 302 wire

Special Features: Packed on tack board to prevent tangling

Lens Stop Spring

Part Names: Spring clip, galvanized wire clip, diffuser spring clip, wire form clip

Industry: Commercial lighting

Application: Spring holds diffuser in the housing

Material: 0.059” galvanized music wire

Special Features: Layer packed at machine to minimize tangling

Mount Spring

Part Names: Spring clip, galvanized wire form clip, linear LED T-grid mount spring

Industry: Architectural lighting

Application: Spring clip mounts 1” linear LED light fixture housing to suspended ceiling T-grid member

Material: 0.051” galvanized music wire

Special Features: Flat loop; two bends close to each other and cut off near bend

Belt or rafter hook for hanging construction power tool

Utility Hook

Part Names: Reversible belt hook, belt clip, adjustable rafter hook, suspension hook, hang hook, utility hook wire form

Industry: Construction power tools

Application: Belt or rafter hook for hanging construction power tool

Material: 0.400” annealed C1065 cold-rolled steel

Special Features: Reduce wire diameter, chamfer, thread, swage (press), austemper harden, electroless nickel plate, nylon thread lock

Hairpin Clip

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

Bait Keeper

Part Names: Fishing bait keeper spring, jig screw lock, corkscrew wire form, stainless steel bait keeper

Industry: Fishing tackle

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.

Material: 0.148” galvanized cold-rolled basic wire

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

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: 0.400” 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

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

Chaoyi Spring manufactures custom wire forms with chamfered, threaded or flattened ends. Using robotic technology, we form special ends in-line to streamline operations.

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Wire Form with Chamfered Ends

Wire Form with Flattened Ends and a Punched Hole

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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 9 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.

Learn More

SPECIAL PACKAGING

Chaoyi 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.

Tack Board Battery Connector

Small Bag of Custom Coil Springs

Helical Springs Strung on Wire Loops

Zip Tied Wire Forms

Wire clips nested in two labelled cardboard boxes

Nestled Wire Form Clips

Multiple Springs Layer-packed

An individually bagged and labelled custom spring clip

Individually Bagged Spring Clips

ASSEMBLY SERVICES

Let Chaoyi 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.

Wire Spring Latch

Oval loop assembled to a custom extension spring

Oval Loop Assembled to Extension Spring

Milk Frother

Heat shrink with a black rubber sleeve on a retainer spring

Rubber Sleeve on Retainer Spring

Ball Chains Assembled to Wire Form

Trot Line Clip

Copper clasp assembled to a custom wire form to create a pull pin

Copper Clasp Assembled Pull Pin

Torsion spring assembled to a plastic molded trigger

Torsion Spring Assembled to Molded Trigger

DOCUMENTATION, CERTIFICATES AND COMPLIANCE

As your trusted wire form manufacturer, Chaoyi 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 0.003” 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

Chaoyi 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

Stainless Steel Wire: 302, 304, 316 and 17-7 PH

Alloy Steel Wire: Chrome silicon

Non-ferrous Alloy Wire: Phosphor bronze, beryllium copper, brass, Monel

High-Temperature Alloy: Inconel

Special Purpose Alloy: Elgiloy, MP35N, Hastelloy C276

Non-ferrous Metal: Copper, Tinned Copper (Buss), Aluminum, Nickel

*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.

Explore the Guide

WIRE FORM FINISHINGS

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.

Wire forms on a conveyor belt receiving in-line stress relief

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.

Coil spring types with in-house dye and paint finishes

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.

Custom wire forms with Magni 525 coat finishing in before and after stages

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.

Wire form with pre-apply inert threadlocking patch

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.

Custom, Made-to-Order Wire Forms

Unique Wire Forms for Many Applications

Precision Wire Forming Capabilities

Custom Threaded Belt Hooks for a Construction Power Tool

See how Chaoyi 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

Chaoyi Spring streamlined a manufacturer’s product packaging by supplying wire clips individually bagged and labeled to include in their circuit board heat sink kits.

Chaoyi Spring Advantage

Contact Chaoyi Spring