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Custom Shaped Wire and Flat Wire

Shaped Wire

We manufacture high tolerance custom shaped wire and flat wire products in a wide range of standard shapes in addition to custom shapes. The range of alloys available is nearly endless with choices from our own high purity wrought powder metallurgy alloys (nickel wire, Pfinodal® wire, Sealvar®, and Nickel Irons) as well as materials from nearly any wire or rod producer on the planet. A comprehensive review of these materials can be found in our Shaped Wire Products Catalog.

Standard Shaped Wire

Standard shaped wire is available from on-site tooling in round, square, and flat wires. Edges of flat wire product can be profiled with square, rolled rounded edges, natural round edges or fully blended round edges. Applications for standard shapes include lighting applications, standard toothbrush wire, electronic connectors, sealing wire and electrical leads.

Wire Edge Capabilities

Square Edge Wire
Flat side with very minimum radius at the corners

Rounded Corner Wire
Flat side wire with a larger radius on the corners

Natural Rolled or Round Edged Wire
No flat on side. Slightly sharp corner where arc meets flats

Full Rounded or Blended Edged Wire
No flat on side. Arc blends into flats, eliminating sharp corners

Custom Shaped Wire

In addition to our standard shapes such as round, square and flat wire, we offer custom wire shape capabilities that are only limited by the imaginations of your designers. Our custom wire shapes are produced to customer drawings and include deep plunging channel wire for superconductors in MRI machines, push-pull controls for the aerospace and marine controls markets, near net shapes for orthodontic use, and specialty shaped toothbrush wires for high tuft retention.

Wire Size Capabilities





0.010" to 0.200"

+/-0.0002" to +/-0.002


0.004" to 0.250"

+/-0.00025" to +/-0.0015"


0.008" x 0.018"

+/-0.001" to +/-0.0035"
Based on ratio of gauge to width

Custom Shapes

Wire Alloy Capabilities


1000 to 7000 Series

Carbon steels

G10060 to G10600


Copper, Copper-Nickel-Tin, Bronze, Brass, Leaded Brass, Nickel Silver, Phosphorus Bronze, Silicon Bronze, Copper-Nickel-Indium

Nickel Alloys

200, 201, 205, 211, 233, 270, Monel®, Inconel®, Incoloy®

Nickel Iron Alloys

Invar® 36, 42, 46, 48, 52, Kovar® (F-15)

Resistance alloys

30-ohm, 60-ohm, 90-ohm, 180-ohm

Stainless steels

300 & 400 Series, 17-4 PH® , A-286

Other alloys

Nickel and Cobalt alloys via powder metallurgy. Other alloys based on availability

Stranding & Bunching Capabilities

Size of Strands

0.005” to 0.062”

Number of Strands

7 Strands to 65 Strands

Packaging Capabilities


3 to 30 pounds

Hex Pails

15 pounds.


50 to 1,000 pounds


30 to 200 pounds


175 to 500 pounds

Straight Lengths

6 inches to 12 feet

Wire Applications

  • Channel Wire for MRI Superconductors
  • Wire for Near Net Shape Orthodontic Brackets
  • Wire for Lids and Leads
  • Toothbrush Staples for Medical
  • Lock Collar Tape for Aerospace Rivets
  • Braid Wire for Braided Cables
  • Posts and Hooks for Jewelry
  • Bunched Wire for Thermo Couples
  • Core Wire for Tire Valve Stems


AMETEK SMP uses a variety of wire forming technology  - drawing, rolling and shaping; provides in-house tooling capabilities; and offers experienced engineering support. We consistently work to tight tolerances in the fabrication of simple and complex shapes for superior dimensional control.

Our expertise in the technology of wrought powders metallurgy enables us to manufacture nickel and custom alloy wire with proven advantages – purity, consistency and close compositional control. These advantages give our customers improved die wear, formability and platability.