Automatic 3D Wire Stripping and Bending Machine (2 - 6 mm²)(10-Step Programmable Bending)

Connector and relay terminal pin forming

Multi-axis terminal pins for PCB through-hole connectors and relay sockets require precise bend geometry where the pin exits the connector body, makes one or more compound bends, and terminates at a defined offset position for board insertion. The EW-08D-1's 3D bending capability forms these compound geometries in a single automated cycle, replacing the secondary manual forming step that conventional 2D bending machines require for non-planar pin shapes.

Automotive sensor lead and bracket wire forming

Sensor lead wires and small bracket-form conductors in automotive applications (temperature sensors, position sensors, small actuator leads) often require a bend sequence that combines a strain-relief loop with a perpendicular mounting tab — a compound 3D shape. The EW-08D-1's 2–6mm² range and 10-step bending sequence cover the wire gauges and form complexity typical of these automotive sensor lead assemblies.

Industrial control and appliance wire form components

Spring contacts, ground strap forms, and shaped jumper wires used in industrial control panels and appliance internal wiring require consistent bend geometry across high production volumes. The EW-08D-1's 500-program memory and 300–600 pcs/h throughput support production lines manufacturing multiple wire-form part numbers across the same wire gauge range.

Electrical component and switchgear lead forming

Formed lead wires for circuit breakers, contactors, and switchgear components often specify a multi-plane bend to route the lead around internal obstructions within a defined envelope. The EW-08D-1's combination of stripping and 3D bending in one cycle eliminates the separate stripping and forming operations typically required when producing these component leads.

Q: What does 3D bending mean, and how is it different from a standard wire bending machine?

A: Standard (2D) wire bending machines form bends within a single flat plane — every bend in the sequence occurs in the same orientation relative to the wire's starting axis, producing flat zigzag or U-shaped forms. The EW-08D-1's 3D bending mechanism rotates the wire's bend axis between steps, so each of the up to 10 bending steps can occur in a different spatial plane relative to the previous one. This allows the machine to produce compound geometries — such as a bend that exits perpendicular to the previous bend's plane — without a secondary manual forming operation, which is required to achieve the same shape on a 2D-only bending machine.

Q: What wire sizes and bending complexity does this machine support?

A: The EW-08D-1 processes 2–6mm² wire with up to 10 programmable bending steps, each with independently adjustable bend angle and bend length. Stripping length is 0–35mm on Side I and 0–30mm on Side II, performed in the same automated cycle as the bending sequence. All parameters are stored across 500 programs for instant recall when switching between different wire-form part numbers.

Q: What is the role of the HIWIN guideway and ATmega chip in this machine?

A: The HIWIN linear guideway (Taiwan) provides the mechanical positioning rail for the bending head, delivering repeatable accuracy across the head's travel range over extended production cycles — a requirement for maintaining bend angle consistency across the 10-step sequence at 300–600 pcs/h. The ATmega microcontroller (US-made) runs the control logic that coordinates bend timing, angle, and sequencing; this processor family is selected for its processing stability under continuous industrial cycling rather than for raw computational speed.

Q: How do I choose between the EW-08A, EW-08B, EW-08C, and EW-08D-1?

A: Selection is primarily based on wire cross-section and bending plane requirement. The EW-08A covers 1–6mm² for general bending applications; the EW-08B extends to 1.5–16mm² for heavier wire; the EW-08C covers 1.5–25mm² for the largest cross-sections in the series. The EW-08D-1 is the model with 3D (multi-plane) bending capability in the 2–6mm² range — select this model specifically when your wire form requires bends occurring in more than one spatial plane, rather than a single flat bend pattern.