United Wire manufactures high-precision flat and shaped wire engineered for demanding electrical applications where performance, consistency, and customization are critical.
Our copper and brass wire supports manufacturers producing busbars, magnet wire components, and splice and crimping systems for high-reliability electrical assemblies.
With decades of experience in precision shaping, we help customers improve conductivity, streamline manufacturing, and enhance end-use performance through optimized wire geometry and edge design.
Busbar Manufacturing
Flat and shaped wire is widely used in busbar systems where efficient current distribution and compact design are essential. United Wire produces tight-tolerance flat wire that delivers:
- Consistent electrical performance
- Reliable downstream fabrication
- Smooth, uniform edges with rounded corners
- Continuous coils with no welds or weak points
Our continuous coil format improves reliability compared to strip material by eliminating breakage risks and reducing handling issues.
Magnet Wire Components
For magnet wire applications, surface finish and edge quality directly impact insulation performance. We produce wire with smooth, controlled edges designed to support enameling and coating processes, helping manufacturers achieve:
- Consistent coating adhesion
- Reduced risk of insulation defects
- Improved process stability
- Reliable long-term electrical performance
Stamped Electrical Components
Precision flat and shaped wire is also an ideal starting material for stamped electrical components where dimensional accuracy, conductivity, and edge quality are critical. United Wire supplies tight-tolerance flat wire used in the production of items such as:
• Electrical housings
• Contact components
• Gaskets and shielding elements
• Sensor components
• Terminals and connectors
• Custom stamped electrical parts
Compared to traditional strip material, our continuous coil flat wire offers several advantages for stamped part production, including improved dimensional consistency across long production runs, smooth, uniform edges (that reduce secondary finishing), reduced scrap and tooling wear, and continuous coils with no welds, minimizing interruption in high-speed stamping.
Splice & Crimping Materials
Our shaped wire solutions are engineered to enhance both mechanical connection and electrical reliability in splice and crimping applications. Custom grooves and profiles can be incorporated to improve:
- Crimp strength and consistency
- Electrical contact integrity
- Assembly efficiency
- Automated production performance
Materials & Alloys Options
We produce precision conductive wire using high-quality copper and brass alloys, including:
- CDA 102 / CDA 110
- CDA 226
- CDA 260
- CDA 510
- CDA 521
- CDA 725
Our manufacturing processes ensure exceptional dimensional control and repeatability, supporting reliable performance in critical electrical applications.
Manufacturing Advantages
United Wire’s production capabilities are designed to support high-volume electrical manufacturing with consistency and efficiency:
- Large packaging options (up to 1,000 lb coils) reduce changeovers and downtime
- Continuous flat wire coils eliminate welds and weak points
- Tight tolerances provide confidence in repeatable part production
- Smooth, uniform edges with rounded corners enhance performance and handling
These advantages help manufacturers maintain stable production while improving finished product quality.
If your electrical application requires precision flat or shaped conductive wire, United Wire can help optimize both performance and manufacturability. Our team provides responsive technical support and custom solutions tailored to your process.
Contact us to discuss your application and explore how precision shaped wire can improve your electrical products.