Wire Form Manufactures
At Airedale Springs, we bring over 80 years of unparalleled expertise to the realm of industrial springs and wire forms. As a leading UK-based company, we take pride in our specialised wire-forming capabilities (also called wire bending), serving diverse industries with precision and excellence.
Our extensive wire range and advanced 3D wire-forming capabilities set us apart as a UK-based wire bending company. With a fleet of 17 cutting-edge CNC machines, we have the capability to transform wire into intricate, custom shapes that meet the unique needs of all our clients, manufacturing products from wire as fine as 0.15mm.
Our Process
Consultation
We work closely with our clients to fully understand the function, dimensions, and operating conditions of the wire form required. If you only have a rough idea, or alternatively detailed technical drawings, our engineers will help refine your concept.
Design
Using our cutting-edge CAD software and 3D modelling tools, we can help you with your wire form design using simulations to test and refine the part if required. This process can eliminate unnecessary revisions during manufacturing. Our experienced technical team uses innovative simulation software to analyse designs for errors before production begins, so you can be confident that the final product will be made to your exact specifications.
Manufacturing
Once the design is approved, production begins using state-of-the-art CNC wire forming machines equipped with a range of tools and special tooling to ensure the highest level of precision. These machines are capable of producing both simple and complex shapes from a wide range of metals, including stainless steel, aluminium, carbon steel, and special alloys.
Types of Wire Forms We Manufacture
In addition to creating high-quality wire forms, we are also coil spring manufacturers, capable of creating products such as compression springs, tension springs, and torsion springs. The type of wire forms we manufacture are:
- Hooks: These provide a quick and secure connection between parts, with an open end that allow them to latch onto other objects. These wire forms are generally used as a point of connection between two parts or components, allowing another item to be connected or suspended. The connection is maintained through tension or gravity.
- Metal Clips & Clamps: These wire forms apply tension to hold components in place, often resembling a ‘U’ shape. Any metal clip or clamp that uses tension to hold items in place is considered a wire form, excellent for securing wires and equipment in different configurations.
- Wire form chains: Constructed by attaching multiple wire forms together to form a chain that can be used to connect parts together.
- Pins: These cylindrical wire forms are used to fasten or locate parts within machinery, securing mechanisms in place.
- Wire Forms with Bends: These are custom-shaped wire pieces with specific bends or angles built into the design.
- Wire rope: Multiple strands of wires twisted or braided together to create strong cables.
- Custom wire springs: Tailored solutions for specific projects where standard approaches don’t work. We collaborate closely with clients to select materials and designs that optimise performance and functionality.
INDUSTRY STANDARDS
We can produce simple or complex wire forms, combining CNC, special tooling and manual processes as appropriate to meet the needs of our customers. Our process is certified to BS EN ISO 9001:2015 standards, ensuring every wire form meets our strict standards.
Our commitment to quality is unwavering. Airedale Springs adheres to industry-leading certifications and standards, guaranteeing that each wire form undergoes rigorous quality control measures before reaching our customers.
Materials
Wire forms can be manufactured from many different materials, meaning we can easily create a product to your exact specifications. The choice of material is highly significant and specific to the application, defining the thickness and shape of the wire.
- Stainless steel– The primary choice for most wire forms, known for its strength, hardness and corrosion resistance, making it perfect for heavy-duty applications.
- Carbon Spring Steel – Popular due to being relatively inexpensive, durable and can be coated in a variety of finishes to improve corrosion resistance or aesthetics.
- Copper has extremely conductive capabilities and resistance to heat, making it ideal for electronics and decorative wire forms.
- Brass – An alloy of copper and zinc that is resistant to corrosion and thermally conductive, popular in the electronics industry.
- Aluminium – Light but sturdy, great for situations where weight matters.
High performance alloys can also be used where resistance to high temperatures is a concern.
Custom Wire Forming Services for All Industries
Wire forms are an extremely versatile component found in almost every industry. We supply wire forms into a variety of sectors, including:
- Agriculture: Wire forms serve as clips and connectors in farm machinery and are often used within the construction of fences and protective cages.
- Electronics: These components are integral to devices such as remote controls, torches, electrical switchgear and light fittings, and are found in tray and routing rings to manage cables effectively.
- Industrial: Wire forms help optimise processes within machinery, functioning as clamps, springs, and guides in various industrial machines, including textile machinery.
- Medical: Used in surgical instruments, dental appliances, hospital beds, mobility tools, bedside machines, dental tools and prosthetics.
- Military: Designed for resilience and reliability in military vehicles, communication equipment and personnel kit bag equipment.
- Oil and Gas: Used in wireline tools for data collection and well interventions, such as pipe recovery and well cleaning, as well as valves and gaskets.
- Sports and Leisure: Found in the construction of masks and guards for contact sports to help meet safety standards, as well as trampolines, exercise machines and bicycles.
We create wire forms for a number of different applications, so be sure to contact our team to see if we can facilitate your request.
Advanced Manufacturing Capabilities
At Airedale Springs, we employ high-speed CNC machines and 3D wire-forming machinery to produce complex wire shapes for the most creative and ambitious projects.
3D wire forms are three-dimensional wire structures used in different sectors for applications such as product displays, artistic installations, custom designs, and functional components in machinery. This technology allows for greater design flexibility and the creation of shapes that may be challenging or impossible to achieve through conventional manufacturing methods.
The process involves precision bending, shaping, and coiling of wire to produce structures with depth, height, and width, going beyond traditional two-dimensional forms.
Our 80th Anniversary Oak Tree Sapling.
Watch the commemorative Oak Sapling wire form being made on our state of the art CNC wire former
Get A Bespoke Wire Form Quote
We have assisted many customers in solving complex design issues, and our engineers have developed innovative solutions leading to substantial cost reductions.
Regardless of the industry, our emphasis on quality guarantees that each wire form we produce meets the highest standards, representing reliable and durable solutions to suit any application.
Do you need standard or custom wire forms for your projects? Feel free to contact us today to explore your options or fill out the form below.
Wire Forms Made Sustainably
At Airedale Springs, sustainability is at the forefront of our operations. We’ve made significant efforts to reduce energy consumption and are working towards being a net energy exporter by 2026. Our building is powered by 438 solar panels, meaning over 80% of our energy used is from renewable sources.
We’ve also cut down on our energy consumption by 20% in the last two years and have won awards for our sustainable methods. Learn more about sustainability at Airedale Springs.
It’s helpful to know where a spring is designed to fit and what the sizes of the hole and shaft are.
Please also let us know of any other important dimensions.
Frequently Asked Wire-Forming Questions
What are Wire Forms?
Wire forms are wire bent or formed into specific shapes for various applications. They can be any size or length and are manufactured using CNC machines that bend, cut, coil and angle wire to precise dimensions.
What is the Difference Between Wire Forms and Springs?
Wire forms are shaped pieces of wire like hooks or clips used to hold or support things. Springs are coiled wires that store energy and push or pull when moved. Choose wire forms for custom shapes and flexibility, and springs for force, tension, or motion control.
What Types of Wire Forms Do You Offer?
We manufacture hooks, metal clips and clamps, wire form chains, pins, wire forms with bends, wire rope, and custom wire springs. We also create compression springs, tension springs, and torsion springs.
Which Materials Are Best Suited for Wire Forms?
Stainless steel, carbon spring steel, copper, brass, aluminium, and high-performance alloys. Material choice depends on your application requirements including strength, corrosion resistance, conductivity, weight, and temperature tolerance.