Custom Wire Forms

At Tollman Spring our custom wire form manufacturing capabilities are computer-controlled on

multi axis CNC wire forming machines. We manufacture wire forms holding angular and

dimensional tolerances across wire diameters of .003 to .156 inches. Critical dimensions are

verified with probe and laser measurement on every run, so complex geometries hold their spec

from prototype through production. And because most parts require no dedicated tooling, you get

that exactness without the upfront cost that slows other suppliers down.

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What is a custom wire form?

Unlike a coiled spring, wire forms can combine bends, loops, hooks and straight legs into a

single part that performs a mechanical function inside a larger assembly. Custom wire forms are

precisely bent and shaped wire component engineered to a specific geometry rather than a

standard catalog profile. We produce these forms to print, matching the exact angular positioning

and leg lengths the application requires.

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Multi-axis CNC wire forming capability

Our wire forming is done on multi-axis CNC equipment, which lets the machine make multiple

bends and complex three-dimensional geometries in a single automated sequence. That matters

for two reasons:

• it holds tighter, more repeatable tolerances than manual forming

• it scales cleanly from a short prototype run to full production without re-engineering the

process

Probe and laser measurement systems check critical dimensions during production to maintain

the angular positioning the part demands. This is how we keep intricate forms within spec at the

small end of the diameter range, where minor deviation has the largest functional consequence.

 

Wire diameter range and material options

At Tollman we produce custom wire forms in wire diameters from .003 to .156 inches. Material

selection depends on the load, environment, and corrosion requirements of your application, and

commonly includes:

• Stainless steel (302, 304, 316) for corrosion resistance and medical or food-contact

environments

• Music wire and high-carbon spring steel for high-strength, cost-sensitive applications

• Phosphor bronze and beryllium copper where conductivity or non-magnetic properties

are required

If your print calls for a material not listed here, send it with your RFQ and our engineering team

will confirm feasibility.

 

Custom wire forms with no tooling charges

The added cost of tooling can drain your resources. At Tollman we manufacture most wire

forms to specifications without requiring costly dedicated tooling. For engineers and

buyers, this means lower upfront costs during prototyping, shorter lead times from concept

to production, and greater flexibility. It also makes low-volume production runs more

economical by avoiding tooling expenses that can drive up costs. That's one reason many

design teams involve us early in the product development process.

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Applications for custom wire forms

Custom wire forms perform mechanical functions in nearly every industry that builds

assemblies, replacing multiple stamped or machined parts with a single lighter, lower-cost

component. Common part types include retention clips, springs clips, brackets, hooks, levers,

connectors, guides, latches, and structural sub-components.

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Medical devices

Actuation components, retention clips, and guide wires inside surgical instruments,

diagnostic equipment, and drug-delivery devices, where small diameters and tight

tolerances are critical, and corrosion-resistant stainless is common.

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Aerospace and Defense

Brackets, retainers, locking clips, and structural forms in airframe, avionics, and ground-

support assemblies, where repeatability and material traceability matter.

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Automotive

Seat and latch components, sensor clips, fuel and emissions system forms, and connector

retainers, often in high volumes where consistent forming holds quality across long

production runs.

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Electronics and Electrical

Battery contacts, grounding clips, terminal forms, and EMI shielding components,

frequently in phosphor bronze or beryllium copper where conductivity or non-magnetic

properties are required.

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Industrial Equipment and Machinery

Levers, guides, linkage components, hooks, and panel retainers used across

manufacturing equipment, pumps, and material-handling systems.

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Appliance and Consumer Products

Wire racks, hinges, detents, and mounting clips that hold function and finish in everyday

hardware.

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Frequently asked questions

 

What is the minimum wire diameter Tollman can form?

Tollman produces custom wire forms down to .004 inches in wire diameter, up to a maximum of .156 inches.

 

Do custom wire forms require tooling charges?

Most custom wire form parts at Tollman are produced without the need for expensive dedicated tooling, which reduces upfront cost and speeds prototyping.

 

How does Tollman hold tolerances on complex wire forms?

Critical dimensions are measured using probe and laser technology during production to maintain the angular

positioning each part requires, on multi-axis CNC forming equipment.

 

Can Tollman produce both prototype and production volumes?

Yes. Multi-axis CNC forming scales from prototype runs through full production without re-engineering the

forming process.

 

What materials are available for custom wire forms?

Common materials include stainless steel, music wire, high-carbon spring steel, phosphor bronze, and beryllium

copper, selected based on load, environment, and corrosion requirements.

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Request a quote

Send your print or specifications and Tollman's team will review feasibility, materials, and

tolerances. Request a quote for your custom wire form project.

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