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 automates this production step by feeding solid wire directly from a spool, straightening it and cutting it to the programmed length.
It provides a repeatable process for both small batches and serial production, helping manufacturers increase output, reduce manual handling and create a more predictable production flow.
The WS-800 is suitable for solid wires with diameters from approximately 0.2 to 1.0 mm, subject to the material properties and application requirements.
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:
Performing these operations manually requires operator time and can introduce differences between production batches. 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 to 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
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 machine can process both short components and considerably longer wire sections. Customer projects have included requested lengths of approximately 3,600 mm.
This makes the WS-800 suitable for a wide range of component sizes and production processes.
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.
Yes. Plated, polished or otherwise surface-sensitive wire may require careful handling to prevent unwanted surface damage during processing.
Straightness requirements differ between applications. The required result should therefore be defined according to the intended use of the wire.
Yes. The required component length, together with the wire properties, should be considered when determining the machine configuration.
Cut-end requirements depend on the application. A standard mechanical cut may be sufficient, while other applications may require additional control of the cut face or secondary finishing.
For demanding applications, the most reliable way to evaluate feasibility is to test the actual production material.
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 temperature sensor manufacturing, electrical heating and resistance components, electronics, medical devices, diagnostics and life sciences, aerospace, precision engineering and specialist wire manufacturing.
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.
