Avoiding design errors in wire bending parts and wire formed parts

Various errors can occur when designing bent wire parts and formed wire parts.
The most common errors and problems can be avoided by:

Incorrect material selection
A common error is the use of an unsuitable material.
Choosing the right material is crucial for the function and service life of the part.

To avoid this:
- Use material databases and special software for material selection
- Contact specialists such as manufacturers of wire bending parts and wire formed parts
- Consider factors such as technical properties, environmental compatibility and availability
- Choose a material that has the required strength, elasticity and resilience

Insufficient consideration of the loads
The actual loads to which the part will be exposed are often underestimated or incorrectly estimated.
This can lead to premature failure.

To avoid this:
- Conduct a detailed analysis of the expected forces and stresses
- Contact specialists such as manufacturers of wire bending parts and wire formed parts
- Consider dynamic loads and fatigue
- Use finite element analysis (FEA) for complex 3D shapes

Neglecting manufacturing aspects
Manufacturability and feasibility are often not sufficiently considered, which leads to problems or increased costs in production.

To avoid this:
- Consider the possibilities and limitations of the bending machines
- Contact specialists such as manufacturers of wire bending parts and Wire forming parts
- Avoid bending radii that are too tight, which could overload the material
- Plan sufficient tolerances for production

Incomplete specifications and inaccurate description of the application
Inaccurate or incomplete specifications can lead to misunderstandings and errors.

To avoid this:
- Precise information on shape, size, material and tolerances
- Contact specialists such as manufacturers of wire forming parts and wire forming parts
- Clear definition of functional requirements
- Consideration of surface properties and post-treatment
- Precise information on external influences and environmental conditions such as resistance to salt water, acids, alkalis or load peaks

Neglect of Overall design
Bent wire parts are often viewed in isolation, without considering their interaction with other components
To avoid this:
- Consider the bent wire part in conjunction with the overall design and especially the connection points to the surrounding structure
- Contact specialists such as manufacturers of bent wire parts and wire moldings
- Consider the possibility of easy assembly and maintenance

By carefully planning and considering important aspects, many of the most common errors in the design of bent wire parts and wire moldings can be avoided.
With a holistic view that includes material, loads, environmental influences, production and function and other aspects, creates the basis for an efficient, durable and successful design of bent wire parts and wire moldings.