Sussex Wire Company Profile
Headquartered in Easton, Pennsylvania, Sussex Wire specializes in the design, manufacturing and distribution of highly-engineered, specialty metal parts and components. The Company, founded in 1973, utilizes cold-forming technology to form metal wire and specialty alloys at room...
Headquartered in Easton, Pennsylvania, Sussex Wire specializes in the design, manufacturing and distribution of highly-engineered, specialty metal parts and components. The Company, founded in 1973, utilizes cold-forming technology to form metal wire and specialty alloys at room temperatures into highly engineered precision, micro-miniature components faster in a more cost-effective manner than traditional machining, stamping, metal injection molding and casting methodologies. Sussex Wire has designed and engineered processes that improve product quality and differentiates the Companys competitive position. The Company serves a variety of global blue chip customers who operate in the medical, electronics, connectors, computer, automobile, transportation, appliance, semiconductors, and glass to metal seal industries.
Warming Up To Cold Forming
New product development teams seeking a competitive edge to allow them to make their electronic devices smaller, appliances more reliable, vehicles safer, or instruments more precise have a variety of choices in sourcing critical micro metal components. Among them are screw machining, stamping, metal injection molding, and cold forming. This brief compares the pros and cons of each technique and explains why cold forming is often overlooked when sourcing a component producer.
Case Study: Specialty Electronic Contact for Sensor Manufacturer
A USA manufacturer of precision micro board-level sensors was sourcing a number of very small, complex rivet-shaped parts from two suppliers, but the customer was experiencing higher than acceptable levels of rejects. Sussex Wire collaborated with the customer's engineering team to provide a better solution, and through the process, influenced the way the company designed their products from the early stages.
Engineered Cold Formed Solutions For The Most Demanding Applications
Cold forming is the application of force with a punch to the end of a precise metal cut-off blank contained within a die. The force causes material plastic flow. Unlike other machining processes, cold forming retains the materials structural properties rather than compromising it. Cold forming is a cost effective method for high volume component heading, upsetting, extruding, sizing, piercing, trimming, thread rolling, blank rolling and pointing operations.
Micro Metal Parts and Terminals: Attributes of a Controlled Finished Surface Suitable For Wire Bonding
This paper identifies a number of considerations in part configuration and finish required to achieve good electrical conductivity in wire bond applications, and notes that many of these features can only be accomplished by cold forming. Alternatives often distort the part geometry, making for an inferior contact surface. Additionally, a perfect part depends significantly on the skill and care of the tooling designer and manufacturer, as well as on a reliable and consistent quality program.
4 Danforth Drive