For over a century, FENN has been known for providing reliable and efficient metal forming machinery, earning the confidence of manufacturers and engineers worldwide.
Among its diverse offerings, FENN’s wire flattening machine and wire shaping solutions stand out as key assets for industries demanding accuracy and repeatability, such as aerospace, medical, energy, and electronics.
What Is Wire Flattening and Shaping?
Wire flattening is the process of reducing the height of round wire while maintaining or modifying its width. Unlike traditional rolling or forming processes, wire flattening emphasizes tight tolerances and specific cross-sectional control. The goal is to create uniform thickness while maintaining surface integrity, which is critical for components used in applications like pacemaker leads or fine ribbon cables.
Materials frequently processed include:
- Copper and copper alloys
- Stainless steel
- Aluminum
- Precious metals like gold, silver, and platinum
Industries using these materials require consistent results at scale. For example, aerospace engineers depend on precision-shaped wires for connectors and shielding, automotive manufacturers rely on them for sensor components, and medical device makers require ultra-clean wire profiles for surgical instruments or implants.
FENN’s Wire Flattening Machinery
FENN manufactures a wide range of wire flattening mills tailored to production demands—from pilot lines to full-scale manufacturing. These machines are engineered to deliver the uniformity and control that engineers expect in critical manufacturing environments.
Key features of FENN’s wire flattening equipment include:
- Precision-adjustable rolls to allow for real-time corrections
- Tight control over thickness and dimensional accuracy
- Compatibility with a wide range of alloys and input wire sizes
- Optional integration with in-line tension control systems
These mills are designed to minimize downtime, improve repeatability, and accommodate both narrow and broad production requirements. Learn more about their full capabilities here: FENN’s Wire Flattening and Shaping page.
Advanced Shaping Capabilities Beyond Flattening
FENN’s machinery doesn’t stop at flat wire. Its shaping systems are capable of producing a variety of cross-sectional profiles that can meet complex engineering standards, all within a single processing line. These profiles include:
- Rectangular
- Oval
- Ribbon
- Custom or complex cross-sections
With these wire shaping machine capabilities, manufacturers can reduce the need for secondary processing or tooling changes. They also support leaner operations and reduce total turnaround time, which is especially valuable when producing precision components at scale.
The ability to form and flatten wire in-line simplifies operations and ensures consistent quality from start to finish, regardless of production volume.
Why Manufacturers Choose FENN for Wire Flattening and Shaping
FENN’s machinery is built for longevity and performance. With installations operating globally across a range of industrial sectors, FENN has built a reputation for:
- Long-lasting equipment backed by robust mechanical design
- Consistent performance under demanding conditions
- Worldwide support network to assist with parts, upgrades, and servicing
- On-site and remote training programs to assist customer teams with setup and operation
Manufacturers in high-stakes industries can’t afford variability. FENN’s wire flattening machines are trusted because they offer repeatable results with every batch.
Meet Your Precision Goals with FENN
FENN continues to support manufacturers with new solutions tailored to modern metal forming needs. If you’re looking for a wire flattening or shaping solution, or simply want to review specs and configurations, visit FENN’s Wire Flattening and Shaping Systems page for additional details.
If you're ready to improve precision, increase efficiency, and support long-term production goals, FENN’s wire flattening and shaping solutions are ready to support you. Contact us today!
