Capabilities Defined

Shear
The starting point for most production parts, the Shear department cuts raw material (wire mesh, perforated and expanded metals) up to 48” in width, over a wide variety of thicknesses and material types, maintaining dimension tolerances up to .0025”. In addition, our calendar operation compresses material, producing a thinner final product, with tolerances up to .001”

Roll
With a vast majority of finished goods resembling a cylinder in shape, the sheared raw material will go through the Forming or Rolling department. Whether utilizing one of our belt, power, crank, or cone rollers, we form the raw material to the desirable shape and diameter, holding strict tolerances.

 

Convolute
Our brand new Intelligent Blade Automatic Pleater with servo controlled sheet feeder, forms raw material in an “accordion” manner, providing increased filtration in the same effective area, as well as increased strength to withstand high flow pressures.

 

Kick Press
The kick press operation provides forming, piercing and assembly operations for small volumes, with minimal tooling investment.
 

Power Press
Automated power press operation, ranging from 15 to 150 tons, has capabilities of forming, stamping and hemming, with close-in and crimping tolerances of .001”. For deep draws and sensitive forming, our air cushion presses can produce a wide variety of parts at the tightest of tolerances. The custom-developed dial presses are cost-effective solutions for high volume orders and includes a 10-station tool-cell.

 

Weld
Certified with aerospace industry standards and over 60 welders on-site at our three facilities, our Weld department specializes in spot, roll and seam resistance welding of any of the wide range of raw materials we fabricate. Whether the part routing requires a large seam welder or a micro welder under magnification, the operation is produced to the tightest of tolerance dimensions for any application.

 

Solder
Certified with aerospace industry standards, the Solder/Braze departments require skilled employees with extensive experience in torch, iron, dip and induction methods. As an alternative bonding operation for higher temperature or chemical interaction environments, we fabricate most raw materials for:  wire mesh to wire mesh; wire mesh to metal; and metal to metal.

 

Silver Braze
Certified with aerospace industry standards, brazers in our Silver Braze department are capable of intricate procedures on a variety of parts.  We perform both free hand and lepel braze operations.
 

Nickel/Gold Braze
Certified with aerospace industry standards, the Nickel/Gold Braze department processes the most demanding of part specifications requiring either nickel or gold braze.  All operations are performed in a certified, non-contaminated, vacuum furnace, with a working range up to 2200 ° F, as well as a clean room for small part assembly and inspection
 

Vacuum Furnace
Up to 2400 ° F working range, the Vacuum Furnace department provides in-house pre-production batch process of annealing and sintering for wire mesh.  Further capabilities include epoxy curing and chemical degreasing.

 

Cleaning
The cleaning department provides a complete cleaning facility, which includes ultrasonic tanks, boiling, tumbling, vibratory and debur operations, as well as potassium permanganate and citric boil operations.  Further capabilities include passivation.

 
Inspection
Incoming material and outgoing finished goods adhere to a certified quality review process in the Inspection department. Capabilities and processes include receiving, WIP, final, first article, and self-release source inspection services. Measuring and monitoring includes in-house XRF gun, caliper, micrometer, microscopic, dimension gauge, optical comparator, pull & bubble test evaluations.
 

Part Identification
The Part Identification department uses the latest in laser, electro chemical etch and vibropeen technology to mark and/or identify parts.
 

Tooling
The starting point of the manufacturing process, journeymen, as well as apprentice, toolmakers in the Tooling department team with the Engineering department to turn machine, compound die, progressive die, jig and  fixture designs into active tooling for the simplest to the most complex parts or components. In addition to new tooling, a big part of the tooling department’s activity is tooling maintenance and value-added engineering to save costs on existing production activities. Wayne Wire is equipped with CNC mills and lathes; manual mills and lathes, drill presses; surface grinders; OD and ID grinders; and saws.
 

Machine Components
Utilizing the latest in CNC milling and lathe technology, Wayne Wire retains the versatility to manufacture many custom fitting designs in-house, for fabrication into a final assembly.
 

Rapid Prototyping
The tooling department enlists the use of our CNC technology to develop prototype tooling with expedited turnaround, leading to accelerated delivery times for sample prototypes.