The Many Uses of Custom Wire Forms

Custom wire forms are essential to applications across various industries. They are highly durable and can fit seamlessly into complex systems and designs, making them an integral component for maintaining and manufacturing industrial equipment. This blog will discuss the different applications of custom wire forms, from custom wire clamps to medical devices, and how they can be used to meet industry-specific requirements.

What is a Custom Wire Form?

Custom wire forms are made by manipulating precisely cut lengths of metal material into complex two-dimensional and three-dimensional shapes. They are frequently used in fastening, supporting, or securing applications and come in a range of sizes and configurations. Read on to learn about common uses for custom wire forms.

Common Applications of Custom Wire Forms

Custom wire forming can meet the specific needs of a wide variety of applications, including:

Automotive

Wire forms are integral to the mechanical function and structural integrity of vehicles. Customizing wire forms results in more durable parts that can withstand vibrations, temperature fluctuations, and other factors commonly seen in automotive applications. As such, they can be used in engine components such as:

• Retaining clips
• Connectors
• Springs

They also play a role in seatbelt systems and airbag deployment mechanisms. Manufacturers can utilize corrosion-resistant, durable materials to ensure that components can fit into tight spaces.

Construction

Custom wire forms are widely used in the assembly of prefabricated modules, as ties in scaffolding, and in concrete reinforcements. They are also commonly found in:

• Anchors
• Connectors
• Reinforcements

Custom wire forming meets the unique challenges of construction applications, maintaining structural integrity while ensuring longevity despite the ongoing influence of environmental factors and physical stressors. Wire form manufacturers can engineer custom wire forms using galvanized or high-tensile steel to increase durability, strength, and load-bearing capacity. These materials are also inherently resistant to corrosion, with epoxy and other special coatings available to further protect custom wire forms from moisture exposure and other environmental conditions.

Electronics

The electronics industry uses wire forms as connectors, clips, contacts, and springs for the following devices:

• Communication infrastructure
• Computer laptops
• Servers
• Smartphones

Custom wire forming for electronics applications involves miniaturization and precision to ensure proper fit and performance in small spaces. Design materials such as stainless steel, copper, brass, and nickel alloys offer excellent conductivity properties with high corrosion and heat resistance. Custom wire forms are intricately designed to maintain consistent connections in electronics while meeting tight tolerances. They can include insulative material coating options to ensure reliability and lasting longevity.

Medical Devices

Custom wire forms are crucial to meet the demands of various medical devices and life-supporting equipment, such as:

• Hospital beds
• Mobility aids
• Orthodontics
• Springs for valves and pumps
• Surgical tools

Custom wire forms for hospitals and healthcare settings can be used to guide, clamp, or otherwise support critical functions in high-stakes scenarios where precision is vital. They must use medical-grade materials to comply with stringent industry regulations and standards. Those materials must also be able to withstand repeated use and exposure to bodily tissues and fluids.

Customization enables precise crafting for exact fits, along with smooth finishes to prevent any infections or adverse reactions.

Custom Wire Forms at Rockford Specialties

As a leading wire form manufacturer, Rockford Specialties Co. has over 40 years of experience providing in-house fabrication, tooling, and engineering services, with the capabilities to produce even the most challenging custom wire form configurations. Whether for medical, automotive, or construction industries, we can help you devise the right solution for your application.

Contact us today to learn how our custom wire forming can transform the performance and longevity of your next project.

Wire Forming in the Furniture Industry

Wire forming is a mechanical manufacturing method with a long history, and it remains a widespread technique today. It involves bending, coiling, shaping, or flattening a length of wire into a desired form, such as a hook, clip, spring, pin, or other shape.

There are several ways to form wire into shapes, depending on the application, component design, and type of wire being used. These include:

• Manual Wire Forming. This uses handheld tools to apply the force needed to create bends and curves.
• Coil Wire Forming. Specialized equipment tightly coils wire into spring shapes.
• Fourslide Wire Forming. A piece of wire is fed into a machine with cams that drive dies into the wire from four different directions to create complex shapes or features.
• CNC Wire Forming. Computer numerical control (CNC) machines are programmed to apply force and bend wire with great precision and speed.

In furniture industry applications, wire forming is often used to make structural, fastening, coiled, and other components. Wire components may be installed in furniture frames with fasteners, attached to the outside of pieces, or even welded into a gridwork or mesh panel. Keep reading for more examples of how wire forming is used.

Office Furniture

Wire formed components are often used to make furniture more durable, ergonomic, and comfortable for the end consumer. The wire material and gauge are determined by things like loading requirements, flexibility versus rigidity of the design, exposure to moisture or outdoor conditions, and secondary finishing processes like paint or powder coating.

Office furniture applications include things like:

• Shelving
• Computer and desk chair springs
• Internal cushion reinforcements
• Pins to secure telescoping tubes on height-adjustable desks and tables
• Hooks used to link rows of chairs
• Storage baskets
• Mesh panels for benches, furniture panels, or tabletops

Consumer Furniture

Home and consumer furnishings often include wire formed elements, some visible and some providing structure inside larger pieces. This category includes both indoor and outdoor items, so options like stainless steel or powder coated or painted steel wire may be appropriate for some applications.

Examples include:

• Reinforcing grids or frames for sofas, lounge chairs, recliners, or dining chairs
• Mattress springs
• Handles, racks, or shelves in bookcases or kitchen carts
• Wire mesh panels on benches or baskets
• Decorative elements on chairbacks, table legs, or shelves
• Lawn chairs, benches, or tables

Stadium Seating

Heavier gauge wire can also be used to reinforce, connect, and secure banks of stadium seating, typically found in areas and other large venues. These applications are often exposed to wind, rain, snow, and UV radiation, and receive heavy use. Seating designed with flip-down seats may also use wire coiled into torsion springs to help retract and hold seats out of the way when not in use.

Custom Furniture Wire Forming From Rockford Specialties

Rockford Specialties serves the furniture and other industries as a full-service wire forming manufacturer specializing in custom steel and stainless steel wire components. We rely on our state-of-the-art metal fabrication equipment and offer secondary services to protect and finish wire components for a variety of applications. Finishing options include plating (i.e., zinc, nickel, chrome), powder coating, electropolishing, nylon coating, and vinyl coating. Laser cutting, welding, and assembly are also available, along with engineering support and prototyping for project success.

For over 40 years we have provided high-quality wire formed components and products in both large and small quantities. We work with companies of many sizes to supply custom wire forms that meet their requirements, from small local businesses to national names like furniture manufacturer Herman Miller.

Contact us today to learn more about our wire forming capabilities and to discuss your application!

Wire Forming for the Food Industry

Commercial kitchens, cafeterias, and other food service and preparation facilities often turn to wire formed products for cooking and storage. Food safe materials like stainless steel and specialized nylon coatings and nickel plating make wire forming a versatile and cost-effective solution for many food and beverage applications. By applying mechanical force to wire material, it can be bent, shaped, flattened, or coiled into specific forms. These can be welded into assemblies, coated, or further finished to meet application needs.

Here we’ll look at some examples of wire formed items commonly used in food and beverage industry settings. We’ll also show how Rockford Specialties can manufacture these and more, drawing on our decades of experience with custom wire forming and laser cutting.

Food Grill Grates and Smoker Racks

Materials for grilling and smoking racks must be sturdy to support the weight of food, and made from stainless steel to withstand high temperatures, flames, and acidic marinades. Heavy gauge wire and secure welding are used to create a grid that resists warping or bending.

Why Custom Wire Forming Capabilities Matter

Custom wire formed grills and racks can be designed for your specific cooking applications, equipment, and processes. Slight variations are needed for baking, grilling, broiling, and smoking, as well as restaurant versus industrial plant settings. Look for a manufacturing partner, such as Rockford, with comprehensive wire forming capabilities to meet your product criteria, such as:

Wire Frying Baskets

Another wire forming application in the food and beverage industry is frying baskets. Wire baskets come in a range of shapes and sizes for preparing items from french fries to breaded chicken to deep-fried confections. Regardless of the food being prepared, fry baskets need to be robust enough to withstand high temperatures and immersion in hot oil, but also lightweight and open to allow the contents to cook evenly. The basket design must also be compatible with frying tanks and drainage racks, and include handles for safe and efficient handling.

Custom Baskets Tailored to the Ingredients and Cooking Process

Look for a wire forming specialist that can manufacture baskets in a range of sizes and wire materials and gauges to meet the needs of the process, ingredients, and production volume. The best suppliers will partner with customers to create products made to their specifications at competitive prices. Services like an in-house engineering and design team and the ability to accommodate short-term and long-term production runs save hassle and improve turnaround times.

Food Racks and Shelves

Racks and shelves are common in ovens and drying units in which food is cooked or dehydrated. Many foods intended for consumption by humans or by animals also require cooling, drying, or storage during production. Sturdy wire shelves and racks help keep products sanitary and allow for airflow to prevent spoilage. They can also be used in retail or wholesale stores to store or display food products.

Construction Details and Finishing Options

Attention to detail is often the difference between a product that is sufficient and one that stands up to continual use, especially when it comes to cooking and food preparation. Precision cuts, well-formed welds, and careful finishing all add up to racks and shelves that are strong and durable for daily commercial or industrial use. Rockford Specialties offers the fit and finish options that make cleaning easier and contribute to a long service life, including:

Wire Forming for Food and Beverage Applications from Rockford Specialties

Established in 1979, Rockford Specialties has been meeting the needs of many industries, including the food service industry, with high-quality custom wire-formed products. Our family-owned company has continued to invest in practices that result in on-time delivery, competitive pricing, quality assurance, and unsurpassed customer service.

Contact us today to learn more about Rockford Specialties and our custom wire-forming capabilities.

Wire Rack Shelving: Versatile Storage Solutions for Industrial Applications

Wire rack shelving is a versatile storage solution that has become an essential component in various industrial settings. With its open-grid design and sturdy construction, wire rack shelving offers efficient organization, easy visibility, and improved airflow for stored items. In this blog post, we will explore the concept of wire rack shelving, its applications in industries such as automotive, food service, and furniture, and how it contributes to effective storage through its unique design.

What is Wire Rack Shelving?

Wire rack shelving, also known as wire grid shelving or wire mesh shelving, is a type of storage system composed of wire grids or shelves supported by metal frames. The wire grids are designed with evenly spaced openings, allowing for increased visibility and airflow. These shelves are commonly made from materials like stainless steel, carbon steel, or galvanized steel wire, providing durability, strength, and resistance to various environmental conditions. The benefits of using wire rack shelving include the following:

• Ease of customization: Wire rack shelving is available in a variety of colors and finishes, and can be easily shaped into different configurations to accommodate any storage requirements.
• Enhanced durability: Constructed of steel posts and support wires that weave into a pattern to create a sturdy shelf, wire rack shelving can withstand upwards of 200 pounds depending on the weaving and steel posts. Industrial wire shelving with welded units may hold up to 800 pounds or more.
• Durable construction: Constructed from premium carbon or stainless steel, making it durable and able to withstand various elements year after year.
• Abrasion resistant: Steel material prevents scuffs and damage, ensuring long-lasting use.
• Strength: Built to withstand a wide range of weight capacities, from a few pounds to hundreds, making them suitable for storing various items.
• Easy to clean: Minimal surface space results in less dust buildup and maximizes airflow, ensuring the stored items remain clean and well-ventilated.
• Versatility: Removable design allows for easy and convenient changes to storage configurations, making it a versatile storage option.

Wire Rack Shelving Applications

With its adaptability and durability, wire rack shelving proves indispensable in diverse and industrial settings, catering to the specific storage needs of various industries.

1. Retail and POP Displays: Wire rack shelving finds extensive use in retail and warehousing environments. In retail stores, wire rack shelving is commonly used to display and organize products such as clothing, electronics, household items, and more. Its open-grid design enables excellent product visibility and easy access for customers.
2. Automotive: In the automotive industry, custom wire racks provide efficient storage and transportation solutions for various parts and components. Wire forming techniques are used to create racks that accommodate the unique shapes, sizes, and weights of automotive parts. Custom wire racks can be designed with specialized features such as dividers, hooks, or adjustable shelves to ensure secure storage and easy access to critical components during assembly or maintenance processes.
3. Food Service: Custom wire racks find extensive use in the food service industry, where specific storage requirements are necessary to maintain food quality and safety. Wire forming allows for the creation of racks that can accommodate different sizes and shapes of food products. Customization options include adjustable shelves, removable partitions, or specialized coatings for improved hygiene and temperature control. These racks facilitate efficient inventory management, proper ventilation, and easy accessibility of perishable goods in commercial kitchens, restaurants, or grocery stores.
4. Furniture: The furniture industry often deals with a wide range of components and materials that require specialized storage solutions. Wire forming enables the creation of custom wire racks that are tailored to accommodate specific dimensions, weight capacities, and storage needs. These racks can be designed to hold upholstery fabrics, wooden panels, metal hardware, or other furniture components. By incorporating custom features such as hanging bars, labeling systems, or stackable configurations, wire racks optimize space utilization and streamline the furniture production process.
5. Laboratories and Medical Equipment: Wire rack shelving plays a crucial role in medical facilities and laboratories. It is utilized to store medical supplies, equipment, and laboratory specimens. The open-grid design allows for proper air circulation, which is important for preserving sensitive materials and minimizing the risk of contamination. Wire rack shelving’s versatility allows for easy customization to accommodate specific requirements, such as adjustable shelving heights or the integration of accessories like hooks or dividers for organizing medical supplies or lab equipment.

Forming Techniques for Wire Rack Shelving

Wire rack shelving is created through the process of wire forming. Wire forming involves shaping metal wire into desired configurations using specialized machinery and tools. The wire is fed into the wire forming machine, where it is bent and shaped to match the dimensions and design requirements of the wire rack shelving. Wire forming techniques allow for the creation of sturdy wire shelves, adjustable heights, and the integration of additional features like hooks or dividers.

Choose Rockford Specialties for Your Wire Storage Needs

Wire rack shelving offers versatile and efficient storage solutions across a wide range of industries. Its open-grid design, durability, and adaptability make it suitable for retail, warehousing, e-commerce, healthcare, laboratories, residential storage, and garage applications. Through the utilization of wire forming techniques, wire rack shelving is manufactured to provide optimal storage capacity, organization, and accessibility. Customize your wire rack shelving with the experts at Rockford Specialties. Contact us to receive a quote and get your shelving solution started.

Why Choose Robotic Welding?

Robotic welding is an automated welding process that uses programmable tools—or robots—to handle and weld parts. When paired with the right applications, welding robots allow manufacturers to increase productivity levels and reduce costs while improving weld quality and consistency. This blog explores the applications and advantages of robotic welding and discusses key questions to consider when choosing between robotic and manual welding.

In general, the best candidates for robotic welding are:

• High-throughput, continuous welding operations
• Applications in which weld quality is critical to part performance
• Welding projects involving high-value parts with little-to-no room for error

While the automotive manufacturing sector has long been the primary adopter of robotic welding, technological advancements have expanded the scope of robotic welding to include everything from medical and OEM part manufacturing to furniture construction. Common uses of robotic welding in these industries include:

• Automotive: Industrial welding robots with extended-reach arms and large payload capacities are used to spot-weld automobile body panels and other large structures. Smaller robots are ideal for welding lightweight parts such as mounts or brackets.
• Medical: In the medical industry, welding robots allow critical medical devices and diagnostic equipment to be produced quickly and affordably without sacrificing quality.
• OEM: OEMs rely on robotic welding for the high-volume production of specialized or safety-critical components used in a range of applications.
• Furniture: The furniture building industry uses robotic welding in several applications, from assembling metal chair bases to creating cabinetry framework and room dividers.

Today’s welding robots can be adapted to perform most types of welding, including:

• Resistance welding
• TIG welding
• MIG welding
• Spot welding
• Arc welding
• Plasma welding
• Laser welding

What are the Advantages of Robotic Welding?

Automated welding offers the following benefits:

Improved Weld Quality

Robotic welding improves all aspects of weld quality, including:

• Integrity: Unlike manual welding, robotic welding allows each welding variable (temperature, torch position, etc.) to be tightly controlled. The mechanized torch combined with the precise movement of the parts during the welding process facilitates a higher-quality weld. Robotic welding systems can also be equipped with vision inspection systems, sensors, and leak detection tests to confirm weld quality.
• Repeatability: With more control over the welding variables, welding robots also enable a more repeatable output. The robot can be programmed to position the parts and welding torch within highly specific tolerances, allowing for nearly identical welds across multiple parts.

Increased Output

Robotic welding eliminates human fatigue, distraction, and other issues that can interfere with productivity. Setup time is minimal and weld speeds are controlled by the machine, allowing for much higher output.

Reduced Scrap

By controlling each welding parameter and eliminating human error, robotic welding significantly reduces scrap and weld rework. In some cases, the cost savings from reduced scrap are enough to justify the equipment investment.

Decreased Variable Labor Costs

In manual welding operations, manufacturers must consider the variable costs associated with worker injuries, sick leave, staff overtime, and other factors that affect production. For example, when a welder misses work, the company loses 8-12 hours of production time, causing variable costs to increase.

With robotic welding, labor costs are lower and more predictable. General machine operators are sufficient to handle most robotic welding operations and are typically more affordable and readily available than skilled welders.

When to Choose Robotic Welding Over Manual Welding

In today’s fast-paced manufacturing environment, automated welding processes are often critical to a company’s ability to remain competitive. Robotic welding can provide large productivity gains, but knowing when and where to implement automation in your welding operation is essential for maximizing these benefits.

Key questions to keep in mind when weighing your welding options include:

• What level of automation will be most beneficial to the overall operation?
• What percentage of the budget can be allocated to the welding portion of the operation?
• What are the strengths and weaknesses of the current welding process?
• Is a high-quality weld essential to the part’s performance or safety in its application? What are the consequences of the customer receiving or implementing a faulty part?
• What types of materials are being welded? Are they compatible with automation?

Robotic Welding Services at Rockford Specialties

When used in high-volume or quality-critical welding operations, robotic welding can significantly enhance productivity and weld quality while keeping labor costs low. At Rockford Specialties, we use our extensive industry experience and comprehensive robotic welding services to help clients optimize their welding operations in a range of industries. Our robotic welding capabilities include:

• MIG welding
• TIG welding
• Resistance + spot welding

To learn more about our robotic welding services and general welding capabilities, visit our welding service page or contact us today.