If you're looking to order some custom wire forms for a new product you're developing, you may not be sure what material to choose. There are a few main options when it comes to wire forms, each with their own pros and cons. Here are some of the most common wire form materials wire form manufacturers work with and the information you need to know about each so you can determine which is best for your specific application.

Stainless Steel Wire Forms

Stainless steel is one of the most popular materials offered by wire form manufacturers. It offers high strength and durability as well as corrosion resistance. Stainless steel wire forms maintain their shape well and can withstand high temperatures. The material is also relatively affordable compared to other metals. However, stainless steel has a higher weight than some other metals. It's also not as malleable as other options, which can limit the complexity of the shapes possible. Overall, stainless steel wire forms are ideal for applications that need strength, temperature resistance, and moderate complexity.

Aluminum Wire Forms

If weight is a top concern, aluminum wire forms may be the way to go. Aluminum has a strength-to-weight ratio superior to steel. It's also highly malleable, enabling the creation of complex or delicate wire form shapes. The trade-off with aluminum is that it doesn't offer the same high-temperature resistance as steel. It also has less overall strength, so it may not work for wire forms under heavy loads. Aluminum wire forms work well for lightweight applications that don't experience extreme conditions.

Copper Wire Forms

Like aluminum, copper offers excellent malleability for intricate wire form designs. It has more strength than aluminum but lower strength than steel. Copper holds up well in higher temperature environments, though not quite as good as steel. Your biggest consideration with copper may be its cost; It's substantially more expensive than steel or aluminum. Copper wire forms are best suited for applications where high thermal conductivity is needed, or for electrical components.

When selecting the right material for your custom wire forms, consider the intended operating conditions, required precision and complexity, weight restrictions, and budget. According to IBISWorld, the wire and cable manufacturing industry market is worth around $14.3 billion, as of 2023. With such a large industry, consulting with experienced wire form manufacturers can help narrow down the optimal metal choice. If you need help to select the best material or creating a wire form, Illini Wire Works, Inc can help. Reach out to us today.