The WS-800 is an automatic wire straightening and cutting machine for solid wire from approximately 0.2 to 1.0 mm in diameter. It feeds wire directly from a spool, straightens it and cuts it to programmed lengths, providing manufacturers with a repeatable process for producing straight, cut-to-length wire components.
The preparation of thin wire can become a significant production bottleneck. Before the wire can be used in a sensor, medical device, resistor, electrical component or mechanical assembly, it may need to be:
Manually unwinding, straightening, measuring and cutting thin wire is a repetitive and time-consuming process. The result can depend heavily on the skill and consistency of the operator, especially when working with fine, hard or spring-like materials. The WS-800 combines these steps in one automated process.
+ Automatic wire feeding directly from the spool
+ Straightening and cutting in one production process
+ Designed for solid wire from approximately 0.2 – 1.0 mm diameter
+ Suitable for different metals and alloys
+ Programmable cutting lengths and different batch sizes
+ Consistent results during serial production
+ Reduced manual handling and operator dependency
| Supported wire diameter | 0.20 – 1.0 mm |
| Cutting method | Hardened steel cutting tool |
| Length tolerance | ±0.25% |
| Wire guidance | Polished ceramic pulley |
| Dimensions | 800x435x250 mm (LxWxH) |
Check the WS-800 datasheet for full specifications
The straightness of manually processed wire can vary between operators and production runs.
The WS-800 provides a controlled and repeatable process. Once the correct machine settings have been established for a particular wire, the machine can reproduce the same straightening and cutting cycle throughout the production batch.
This helps manufacturers improve consistency and makes subsequent production operations easier to control or automate.
The wire is processed directly from the spool.
Automatic feeding eliminates much of the manual handling involved in unwinding and positioning individual wire sections. It also allows the machine to operate for longer production runs while the operator performs other tasks.
The design of the feeding and payoff arrangement can be adapted to the spool, coil or wire-delivery format used in the customer’s production process.
Fine wire can retain the curvature of its spool or exhibit spring-back after straightening. The precise behaviour depends on its diameter, tensile strength, hardness, alloy and previous processing.
The WS-800 straightening system is configured according to these material characteristics.
Depending on the application, different straightening concepts or machine adjustments may be evaluated to obtain the required result.
The required wire length can be entered through the machine controls, allowing the WS-800 to produce repeated wire sections according to the selected production parameters.
The achievable component length depends on the machine configuration and downstream product handling. Customer projects have included requested lengths of approximately 3,600 mm, demonstrating that the WS-800 is not limited to short wire components.
The WS-800 performs repetitive wire preparation automatically.
Operators no longer need to measure and cut every individual wire section by hand and can instead focus on assembly, quality control or other value-adding activities.
Qualified production personnel are increasingly difficult to find.
Automating repetitive wire-processing operations helps manufacturers use their available workforce more effectively and reduces the dependence on experienced operators for routine production tasks.
The WS-800 is designed for solid wires with diameters from approximately 0.2 to 1.0 mm, but diameter alone does not determine whether a wire can be successfully straightened and cut.
Wire behaviour can vary considerably, even between wires with similar nominal dimensions. Material properties, spool condition and the required result can all influence the achievable straightening and cutting performance.
Wire behaviour depends on properties such as tensile strength, hardness, ductility, elasticity and spring-back. Wires with the same diameter can therefore require different machine settings.
Wire retains curvature from being stored on a spool. The degree of spool memory depends on the wire, spool diameter and winding condition, which is why testing with the actual production spool is preferred.
This can be particularly important for plated wire, polished wire, precious-metal wire, medical wire, electrical contact materials and components with cosmetic surface requirements.
There is no universal definition of acceptable straightness for every wire application. A thermocouple element, medical needle blank, connector pin and resistance wire can each have different straightness requirements. For this reason, feasibility should be evaluated against the customer’s actual dimensional or functional requirement rather than a generic visual definition of “straight”.
Yes. The required component length, together with the wire properties, should be considered when determining the machine configuration.
The required cut quality can depend on whether the wire will subsequently be welded, inserted, crimped, sharpened, polished or assembled into another component.
Because thin-wire behaviour cannot be predicted from diameter alone, TMF recommends application-specific testing for demanding materials or tight straightness, surface and cut-end requirements.
Testing can be used to evaluate:
Once a suitable configuration has been established, settings can be recorded and reused for recurring production.
From thermocouple elements and resistance wire to medical needle blanks, connector pins and precision industrial components, thin solid wire is used in an enormous range of manufacturing processes.
Applications for the WS-800 can be found across:
Explore the different applications of the WS-800 and discover how automated wire straightening and cutting can support your manufacturing process.
The WS-800 provides reliable straightening and cutting of small-diameter solid wire, delivering consistent results while reducing manual handling and improving production efficiency.
