Shaped wire

Fort Wayne Metals is at the forefront of the exciting shaped wire technology. Our success with flat wire processing has allowed us to push our capabilities into a new arena.

Features and benefits

Shaped wire allows you to lower overall manufacturing and product costs by reducing assembly time and machining processes. This rolled wire provides a good cast and is available in all alloys. It is a near net shape product and is able to achieve very unique geometries.

Popular Shapes


Half Round, Over Half Round and Under Half Round geometries can be achieved. D-Wires are often used as the product or also as tooling. D-Wires can provide unique lumen shapes in plastic components.

Sizes: 0.0015” (0.0381 mm) x 0.004” (0.1016 mm) to 0.040” (1.016 mm) x 0.080” (2.032 mm)

Crescent Wire

Sizes: .0058” (.147 mm) x .010” (.254 mm) to .040” (1.016 mm) x .060” (1.524 mm)

Pie Wire

Sizes: 0.0056” (0.142 mm) x 0.007” (0.177 mm) to 0.030” (0.762 mm) x 0.045” (1.143 mm)

Angle: 45° to 120°

Triangle Wire

Sizes: 0.0045” (0.1143 mm) x 0.0085” (0.216 mm) to 0.040” (0.1.016) to 0.045” (1.143 mm)


Sizes: 0.006” (0.152 mm) x 0.006” (0.152 mm) to 0.070” (1.778 mm) x 0.070” (1.778 mm)

Max Width/Thickness Ratio of 2:1


Thickness Tolerance

±5% of the thickness rounded up to the next 0.0001", with a minimum of ±0.0002".

Width Tolerance

±5% of the width rounded up to the next 0.0001",  with a minimum of ±0.0002".

Tensile Strength

Tensile strength ranges from annealed to spring temper can be achieved in most shapes and alloys. Wires with unique geometries should be specified with a Break Load requirement, and use the tensile strength calculation as a reference due to the difficulty of measuring the cross sectional area.