5 Common Mistakes When Designing Custom Wire Forms (and How to Avoid Them)

Custom wire forms are incredibly versatile, but designing them isn’t as simple as bending wire into shape. Even seasoned engineers can make mistakes that lead to costly delays or product failures. Here are five common pitfalls—and how to avoid them.

1. Ignoring Material Properties

Not all wire is created equal. Using the wrong material can lead to premature wear, corrosion, or even catastrophic failure.

  • Solution: Match the material to the application. For example, stainless steel is ideal for corrosive environments, while music wire offers superior strength for high-stress applications.

2. Overlooking Tolerances

Wire forms often need to fit into precise assemblies. Even a slight deviation can render the part unusable.

  • Solution: Clearly define tolerances with your manufacturer. At Daichi Springs, we use advanced CNC machinery to ensure every wire form meets exact specifications.

3. Neglecting Stress Points

Sharp bends or uneven stress distribution can create weak points, leading to cracks or breaks.

  • Solution: Use gradual curves and avoid abrupt angles. Our engineers often recommend radius bends to distribute stress evenly.

4. Failing to Consider End-Use Conditions

A wire form that works perfectly in a lab might fail in the field due to temperature fluctuations, vibrations, or exposure to chemicals.

  • Solution: Test prototypes under real-world conditions. We simulate extreme environments in our testing facility to ensure durability.

5. Skipping Prototyping

Jumping straight to mass production without testing a prototype is a recipe for disaster.

  • Solution: Always start with a small batch. At Daichi Springs, we offer prototyping services to help clients refine their designs before scaling up.

By avoiding these mistakes, you can save time, reduce costs, and ensure your wire forms perform flawlessly.

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