Shaped Wire Drawing Dies

Name: Shaped Wire Drawing Dies
Brand: Relink

Shape dies (profile dies) turn round or pre-shaped wire into non-circular sections.

These dies are essential for producing specialized wire profiles that standard round dies cannot achieve, enabling manufacturers to meet demanding requirements for form, function, and performance in modern applications.

Overview

How to Start Your Trial Order?

Core Design and Materials

Available with a PCD core, or in tungsten carbide where cost matters more than life; both in stainless steel casings. Nano-coated shape dies are also available.

PCD shape dies last much longer than carbide; how much depends on wire and pass.

Supported Profiles and Customization

Relink Shape Dies support a broad spectrum of standard and bespoke geometries to suit diverse production needs:

Standard shapes: rectangles, squares, hexagons, octagons, ovals, triangles, trapezoids, flats, and half-rounds.
Custom profiles: Fully tailored designs including D-shapes, teardrops, stars, irregular polygons, gear-like contours, or any client-specified cross-section based on detailed drawings, CAD files, or physical samples.

Profiles are made to your drawing, CAD file or sample, to the tolerance you specify — confirmed per order. We can advise on the pass sequence from round to profile.

Key Performance Advantages

Relink Shape Dies excel in high-speed, high-volume environments thanks to several critical benefits:

Superior Wear Resistance & Uniform Wear: PCD’s low friction coefficient and high thermal stability minimize abrasive wear, prevent uneven die enlargement, and ensure long-term dimensional stability—resulting in fewer profile deviations and reduced scrap rates.
Exceptional Surface Finish: Fine surface finish on the drawn wire, often reducing downstream polishing.
Versatile Material Handling: Optimized for non-ferrous metals like copper and aluminum (ideal for PCD), as well as harder alloys, stainless steel, and specialty wires (WC options provide balanced toughness for abrasive or high-strength materials).
Pressure & Non-Pressure Flexibility: Engineered for both lubricated pressure-assisted drawing (enhancing flow and finish) and dry/non-pressure setups, making them adaptable to various machine configurations.

Industry Applications & Value Proposition

Relink Shape Dies are widely deployed across industries that demand precise, non-round wire geometries:

Automotive: Flat or rectangular conductors for wiring harnesses and high-current cables.
Electronics & Telecommunications: Precision profiles for enameled magnet wire, connectors, and high-frequency cables.
Industrial Manufacturing: Shaped wires for springs, fasteners, filters, and architectural applications.

By choosing Relink Shape Dies, manufacturers gain measurable ROI through:

Extended tool life that slashes replacement frequency and inventory costs.
Consistent tolerances that improve downstream processing yield.
Reduced material waste and energy use for more sustainable operations.

Uniform Polishing

Provides consistent high-quality finishes.

Reduced Maintenance

Long wear life means fewer die changes.

Low Friction

Ensures smooth wire drawing without premature die wear.

Relink Shape Dies Feature

Exceptional Durability: PCD composition ensures uniform wear and minimal breakage, extending die life and reducing replacement frequency.
Precision Engineering: Profiles are made to your drawing, CAD file or sample, to the tolerance you specify — confirmed per order.
High-Speed Compatibility: Low friction and excellent thermal conductivity support faster drawing speeds without overheating, ideal for continuous production lines.
Customizable Designs: Tailored to specific wire materials (e.g., soft copper or hard alloys) and shapes; Supports multi-pass drawing for complex profiles.
Cost Efficiency: Lower material waste and downtime; Optional recyclable casings for sustainable operations.
Versatile Applications: Perfect for enameled wires, flat cables in EVs, photovoltaic ribbons, and precision conductors in electronics.
Easy Integration: Insert-style for quick swaps; Compatible with lubricants and dry drawing processes.

Specifications

Materials: Polycrystalline Diamond (PCD) core for high hardness and thermal conductivity; Nano-coated (CVD diamond layer on tungsten carbide) for long wear life; Tungsten Carbide (WC) options for cost-effective durability; Stainless steel casing for corrosion resistance.
Shapes Available: Standard profiles include flat, rectangle, square, hexagon, octagon, oval, triangle, and trapezoid; Custom shapes based on client drawings (e.g., D-shaped, half-round, or irregular geometries).
Size Range: Inlet diameters from 0.05 mm to 50 mm; Outlet profiles up to 30 mm in width/height; Reduction angles from 10° to 30° for optimal flow.
Tolerances: to your drawing, confirmed per order.
Lifespan: PCD shape dies last much longer than carbide; how much depends on wire and pass.
Compatibility: Fits major drawing machines (e.g., multi-pass wire drawers, extrusion lines); Available in cased or insert formats for easy replacement.
Customization Options: CNC-machined to exact specs; Optional coatings (e.g., CVD diamond) for enhanced lubricity and heat dissipation.

Compare

Comparison

Shape dies come nano-coated, with a PCD core or in tungsten carbide. Which one pays off depends on the wire material, the profile and the run length — see the full comparison of die materials.

Wire Drawing Die Materials Compared

FAQ

Do you offer samples or trials?

Yes. Orders start from one piece, and samples or small trial batches can be arranged with our sales team. Email [email protected].

What industries benefit most from Shape Dies?

Wire and cable manufacturing, automotive wiring, and electronics conductors.

How do I maintain Relink Shape Dies?

Clean the dies regularly with a non-abrasive solution, and keep the lubricant clean.

Are these dies suitable for high-speed production?

Yes. Nano-coated, PCD and carbide shape dies are all used on high-speed lines; the achievable speed depends on the wire material, the profile and the lubrication.

What is the typical lifespan of a Relink Shape Die?

It depends on the wire material, the profile and the speed. PCD shape dies last much longer than carbide ones.

How do Shape Dies differ from round wire drawing dies?

Shape Dies create non-circular profiles (e.g., rectangular for flat cables), offering better control over cross-sections compared to standard round dies, which are limited to circular outputs.

Can you produce custom shapes?

Yes. Shape dies are supplied to your drawing, CAD file or sample. Send us the profile, the wire material and the dimensions, and we will quote.

What materials are Relink Shape Dies made from?

Nano-coated or PCD where die life matters most, or tungsten carbide where cost matters more than life.