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Custom Cold-Formed Micro Components

Sussex Wire manufactures precision cold-formed micro-components built to meet exact customer specifications. We produce a wide range of custom parts鈥攆rom micro pins and medical leads to wire forms and electrical contacts鈥攅ngineered for performance in medical devices, electronics, and other high-reliability applications. Every part is made-to-order based on your design, material, and production requirements.

Cold-Formed Micro Components

Custom micro components manufactured with precision cold forming for strength, consistency, and cost-efficiency.

Cold-Formed Micro Components
Cold-Formed Pins

Headed, grooved, and multi-diameter pins designed for high-performance applications in medical, electronic, and mechanical assemblies.

Cold-Formed Pins
Connector & Electrical Pins

Wire bondable and hermetically sealed pins for relays, sensors, and compact electronic devices鈥攆ormed to tight tolerances.

Connector & Electrical Pins
Custom Micro Fasteners

Threaded and non-threaded fasteners, rivets, and studs built for strength, small form factor, and repeatable assembly.

Custom Micro Fasteners
Custom Machined Components

Tight-tolerance parts machined for complex features, specialty finishes, or geometry not suitable for cold forming.

Custom Machined Components
Eyelets, Hubs & Inserts

Precision components used for alignment, fastening, or mating in medical, electronic, and consumer devices.

Eyelets, Hubs & Inserts
Four-Slide & Miniature Stampings

Small stamped parts with clean forms and complex bends鈥攊deal for compact mechanical and electromechanical assemblies.

Four-Slide & Miniature Stampings
Wire Forms

Cold-formed wire components shaped to exact geometries for routing, retention, or contact within assemblies.

Wire Forms
Standoffs & Spacers

Miniature components used to maintain consistent spacing in PCB, connector, or structural assemblies.

Standoffs & Spacers
Miniature Medical Components

Cold-formed micro parts designed for implantable and wearable medical devices, drug delivery systems, and surgical tools.

Miniature Medical Components
Single & Multi-Threaded Leads

Cold-formed leads and pins with one or more threads鈥攅ngineered for electrical, assembly, or signal applications.

Single & Multi-Threaded Leads
Caps & Buttons

Small-scale closures and formed tops for mechanical assemblies, sensors, and drug delivery systems.

Caps & Buttons

Built to Your Specs


Finding the right partner to produce micro components with tight tolerances, specialized materials, and scalable production can be a challenge. Sussex Wire simplifies the process by delivering cold-formed micro components engineered to meet your exact design and performance requirements.

We manufacture custom micro components in diameters ranging from .007" to .400" and lengths from .040" to 3.00", all built to spec with precision processes and expert support.. Every product we make is custom鈥攄eveloped in partnership with your team and built to perform in real-world applications.

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How We Manufacture Precision Micro Components


Sussex Wire uses cold heading as our core manufacturing process鈥攄elivering custom micro components with exceptional accuracy, strength, and repeatability. For parts requiring additional complexity, we integrate advanced operations such as CNC machining, thread rolling, EDM cutting, and four-slide forming.

We support components with tolerances as tight as 卤.0003", all manufactured in the U.S. under strict quality control.

Explore Our Capabilities

Why Engineers Choose Sussex

  • Cold forming for cost efficiency and strength
  • Tight tolerances for critical performance
  • Prototype-to-production scalability
  • Support for specialty materials (52 Alloy, Kovar, copper cored, etc.)
  • ISO 9001 and ITAR certified
  • Responsive engineering support from design through delivery

Have a Part in Mind? Let鈥檚 Build It.

Our team is ready to review your design, answer technical questions, and help you explore cold-forming solutions tailored to your application.

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