Specifically Manufactured Custom Wires

We offer a variety of drawn wire services, including annealing, straightening, grinding and polishing. We can draw custom profiles in all alloys with diameters ranging from .002″ to .125″.

Our team is dedicated to providing the highest quality of drawn wire with precise tolerances, ensuring our clients receive products that meet their specific needs and requirements.

Drawn wire is produced by pulling metal through precision dies to reduce its diameter and refine surface finish. This process is the primary manufacturing method used at CFW to produce precision round wire products. 

We draw wire in a wide range of alloys with diameters ranging from .0004” to .040” (10 µm to 1 mm), while maintaining tight dimensional tolerance for demanding applications. For applications requiring enhanced surface quality, inquire about our ultrafinish options.

For various electrical applications, our insulated wire services are second to none. We have the capabilities to provide both single and multi-conductor insulated wires in a wide range of materials such as PVC, Teflon, rubber and more.

Our team is experienced in working with different insulation thicknesses, colors and markings to meet the unique needs of each project. We also offer custom cutting and stripping services for precise measurements.

Insulated wire is produced by applying controlled enamel coatings to precision drawn wire to provide electrical insulation and environmental protection. CFW applies a wide range of insulating materials, including ceramic, PTFE, nylon, and polyester coatings.

These coatings can be applied to most alloy wires with diameters ranging from .0009” to .021”  (25 µm to 0.5  mm), producing insulated wire for demanding electronic applications. Coatings can also be used to bond multiple conductors together to create bifilar or duplex wire constructions when required. 

Our PTFE insulated wire is specially designed to withstand extreme temperatures and harsh environments. It is known for its excellent chemical resistance, low friction, and non-stick properties.

We offer PTFE insulated wire in various configurations including solid or stranded conductors, shielded or unshielded options, and different gauge sizes. Our team can also provide custom designs to meet specific requirements.

PTFE insulated wire provides exceptional chemical resistance, low friction, and stability in extreme temperature environments. At CFW, a proprietary coating process applies a thin, uniform layer of PTFE directly on precision wire without the use of primers. 

This approach allows PTFE insulation to be applied to fine and ultra-fine wire sizes that are often too small to be coated with conventional PTFE methods, while maintaining tight dimensional control and minimal added bulk. PTFE coatings can be applied to a wide range of alloys and conductor configurations, including single conductors, bifilar pairs, and stranded constructions.

Our custom wire technologies also include electroplated wire, which is used in a variety of industries such as automotive, electronics, and medical. The electroplating process involves coating a conductive material with a thin layer of metal to enhance its properties.
Some benefits of electroplated wire include improved corrosion resistance, increased

durability and strength, and enhanced electrical conductivity. We offer various plating options such as gold, silver, tin, nickel, and copper.

Electroplating is the process of depositing a thin layer of metal onto a conductive substrate to enhance properties such as corrosion resistance, conductivity, and solderability. As part of our portfolio of custom wire technologies, CFW offers in-line reel-to-reel electroplating for spooled wire and barrel plating for cut pieces.

We plate both round and ribbon wire using materials such as gold, silver, tin, nickel, and copper to meet specific electrical, environmental, and performance requirements.

For applications that require a flexible and compact wiring solution, flat ribbon wire is an ideal choice. It consists of multiple insulated wires that are placed side by side and then laminated together to form a flat ribbon shape. This type of wire is commonly used in electronic devices such as computers, televisions, and mobile phones.

One major advantage of using flat ribbon wire is its space-saving design. It allows for more efficient use of limited space within devices, making it a popular choice in the electronics industry. Additionally, the laminated structure provides better protection against electromagnetic interference (EMI) and crosstalk compared to traditional round wires.

Flat ribbon wire is produced by rolling round wire through precision mills to create a controlled rectangular cross-section. CFW’s Precision rolling mills produce flat wire with clean, oil-free surfaces and tight dimensional tolerances. 

Ribbon wire is used in applications such as lead ribbon, voice coil winding, and microelectronic interconnections. Thickness can range from .0002” to .050” (5 µm to 1.3 mm) and widths from .002” to .100” (51 µm to 2.54 mm), depending on the material and required dimensions. 

Our drawn wire manufacturers also offer annealing services, which is a heat treatment process that improves the ductility and electrical conductivity of the wire. This involves heating the wire to a specific temperature and then cooling it down slowly to achieve desired mechanical properties. Annealing can also reduce residual stresses in the wire, making it less prone to breakage or deformation during use.

Annealing is a heat treatment process used to relieve stresses introduced during wire drawing and improve ductility and metallurgical uniformity. Proper annealing allows the wire to bend and form without premature breakage while providing more predictable mechanical performance in demanding applications. 

As experienced drawn wire manufacturers, CFW offers both reel-to-reel strand annealing, where wire is continuously heat-treated as it passes through a controlled furnace, and batch annealing for smaller production volumes. Annealing can be performed in controlled atmospheres to prevent oxidation and maintain material purity.

Some of our clients require their drawn wire to be packaged in specific ways for ease of use and transportation. Our manufacturers offer various spooling options such as plastic, wooden, or metal reels that can accommodate different lengths and weights of wire. This ensures that the wire remains organized and protected during shipping and storage.

CFW offers a range of packaging and spooling options to support safe handling, storage, and integration in customer production processes. Wire can be supplied on standard or bonding spools, or provided as cut-to-length pieces, depending on application requirements.

Packaging configurations can be tailored to customer specifications, including cleanroom-compatible blister packaging for medical and electronic components. 

We also offer stranding and twisting services for various custom wire technologies, including stranded wire. Stranded wire is made up of multiple small wires twisted together to form a larger conductor, providing flexibility and improved conductivity compared to solid wire. Our manufacturers have advanced machinery and skilled technicians to produce high-quality stranded wires with specific configurations tailored to our clients’ needs.

Stranded wire is produced by twisting multiple fine conductors together to form a single flexible cable. CFW incorporates precision stranding and twisting as part of our custom wire technologies, supporting fine wire applications that require flexibility, durability, and consistent electrical performance.

Using our in-house designed stranding equipment, we are able to strand extremely fine wire without stretching or damaging the individual conductors. Typical configurations include twisted pairs, 7-strand, and 10-strand constructions, with custom constructions available. Our stranded wire conductor diameters range from .0009” to .098”  (25 µm to 2.5 mm), depending on the material and application requirements.

For any of our custom wire technologies, we conduct rigorous testing to ensure the highest quality and reliability. Our testing procedures include high voltage tests, insulation resistance tests, and mechanical strength tests. We also offer customized testing options to meet specific requirements or industry standards.

Quality testing is performed to verify that wire meets the dimensional, mechanical, and electrical specifications required for each application. For all of our custom wire technologies, CFW conducts in-house inspection and testing to confirm conformance to customer requirements.

Testing capabilities include dimensional inspection, tensile testing, and electrical resistance measurement using precision instrumentation capable of resolutions down to 0.00001″ and accuracies of ±0.00005″. Customized testing can also be performed to meet specific customer requirements or applicable industry standards.

Our Ultra Finish process produces round wire with the tightest dimensional tolerances and surface finish possible by drawing through custom diamond dies. This process is ideal for applications that require minimal surface defects, such as medical devices and high-precision electronics. 

Our Ultra Finish process produces round wire with the tightest dimensional tolerances and surface finish possible by drawing through custom polycrystalline diamond dies. Standard Ultra Finish size ranges are .0003” to .004” (7.6 µm to 102 µm), with roundness as tight as .000025” (0.64 µm). This process is ideal for applications requiring minimal surface defects, such as medical devices and high-precision electronics.

At California Fine Wire Company, we pride ourselves on providing exceptional customer service. Our knowledgeable staff is always available to answer any questions and assist with finding the right wire solution for your needs. We also offer quick turnaround times and flexible shipping options to ensure prompt delivery of your order.

As a producer of premium quality custom wire technologies at California Fine Wire Co. we are adept at accommodating special handling and processing needs with precision and efficiency. Many customers in the aerospace, medical, defense, and electronics industry use our products in unique applications which require secondary processes not available from standard wire stock suppliers.

As a producer of premium custom wire products, California Fine Wire Co. is equipped to support specialized handling and processing requirements with precision and efficiency. Many customers in the aerospace, medical, defense, and electronics industries rely on our wire products for highly specialized applications that require secondary processing beyond what typical wire stock suppliers can provide.

Our team regularly works with customers to incorporate additional handling, finishing, and processing steps that ensure the wire arrives ready for its intended application. By integrating these processes directly into our manufacturing workflow, we help streamline production for our customers while maintaining the tight dimensional tolerances and material integrity required for high-performance applications.