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Custom Cold-Formed Micro Components Built for Precision, Volume, and Performance

End-to-End Manufacturing for Micro-Scale Precision

Our core process is cold heading, supported by a full range of precision manufacturing operations. This allows us to create complex geometries with minimal material waste, superior strength, and faster cycle times than traditional machining. Our manufacturing capabilities include:

• Cold Heading / Cold Forming – ÌýOur primary process - ideal for high-volume production of precision components with excellent material efficiency and strength.

• Fourslide & Multi-Slide Forming – Used for small stamped or formed parts with complex bends, folds, or multi-plane geometries.

• CNC Screw Machining – Enables secondary operations and complex features not suitable for cold forming alone—tight tolerances, threads, undercuts, and more.

• Thread Rolling & Tapping – Cold-worked threads that offer better fatigue strength and finish than cut threads—available in single or multi-thread configurations.

• Wire EDM Cutting – Ideal for tight-tolerance trimming or slotting of difficult-to-machine materials with high precision and clean edges.

• Roll Forming – Used to shape detailed profiles in small parts requiring consistent cross-sections.

• Bending – Precision forming of wire and strip components for complex shapes and multi-axis applications.Cleaning, Finishing & Plating – Full range of part finishing operations to meet cosmetic, functional, and corrosion resistance requirements.

• Cleaning, Finishing & Plating – Full range of part finishing operations to meet cosmetic, functional, and corrosion resistance requirements.

• Dimensioning & Tolerancing – Final dimensional adjustments to ensure components meet exacting performance standards and fit.

Value-Added Services

In addition to our core manufacturing capabilities, Sussex Wire provides a range of value-added services that support your project from concept through delivery. These services are designed to streamline development, reduce lead times, and ensure production success—whether you're building a prototype or scaling to full volume.

• Design & Engineering Support – ÌýCollaborate early with our team to optimize your part for manufacturability, performance, and cost efficiency.

• Prototyping & Low-Volume Production – ÌýAccelerate early-stage development with flexible, fast-turn manufacturing for prototypes and pilot runs.

• First Article Inspection (FAI) – ÌýReceive full dimensional verification and documentation of initial parts prior to production release.

• PPAP (Production Part Approval Process) – ÌýComprehensive validation packages for customers in regulated industries that require formal approval documentation.

• Inspection – ÌýIn-process and final part inspection using calibrated, NIST-traceable equipment to ensure quality and consistency.

• Scalable Solutions – ÌýSupport for both short-run and high-volume production—with systems designed to scale as your needs evolve.

• JIT Delivery – ÌýJust-in-time shipping options that help reduce on-hand inventory and align with your production schedule.

Materials We Work With

We work with a wide range of standard and specialty materials, including those known for their strength, conductivity, corrosion resistance, or cold forming challenges. Whether you're working with copper-cored materials, medical-grade stainless, or exotic nickel alloys, our team helps you choose and manufacture components that meet both performance and production goals. Common materials include:

Quality Certifications & Standards

Our quality systems and documentation processes meet the strictest standards for traceability, compliance, and performance—so you can move forward with confidence. View Our Full List of Available Certifications