Sussex Wire specializes in the design and manufacture of custom, cold-formed metal parts in mini- and micro-geometries to complex and precise tolerances.

Mechanical design and assembly firms turn to Sussex Wire for their most advanced near-net-shape part requirements to eliminate material scrap, increase mechanical strength and reduce costly secondary and assembly operations. Headquartered in Eastern Pennsylvania, Sussex is a global design and manufacturing company of precision miniature and micro metal components. We employ state-of-the-art proprietary part progression and tool design modeling techniques developed over 40+ years of company experience to produce optimal component formation and extended die life management.

Sussex Wire can produce radii, tapers, eyelets, knurls, edge break and complex geometric shapes with control tolerances to +/-.0005”. We are known for these manufacturing operations:
  • Cold Forging
  • Roll Forming
  • Coining
  • EDM
  Materials include:
  • Aluminum
  • Copper core steels and alloys
  • Stainless, Inconel & Hastelloy
  • Kovar
  • 52 & 42 alloy
  • Tantalum
  • Molybdenum
  • Platinum, palladium, silver and other exotic alloys

Sussex Wire’s manufacturing and design engineers use vertically integrated capabilities such as finite element analysis, prototyping, tooling, custom turn-key manufacturing technology and cellular work centers to produce small specialized parts. Examples include cold headed pins, glass-to-metal pins, eyelets, electrical contacts, micro valve parts and other precision metal components, all with tolerances often beyond the capabilities of traditional machining or stamping parts manufacturers. Sussex Wire's customers depend on our unique process design, LEAN manufacturing, Automated Optical Inspection (AOI) and six-sigma quality system to aid customers in keeping automated guidance systems on target, medical implants 100% reliable, automotive airbags failsafe, defense products fully compliant with mil-spec standards, and for delivering critical functionality to many other applications.

Sussex Wire applies cold-forming and roll-forming manufacturing techniques to shape metal wire and specialty alloys at room temperatures into highly engineered, precision, micro-miniature components in a more cost-effective manner than traditional machining, stamping, metal injection molding and casting methods can. Sussex serves global blue chip customers who operate in the medical, electronics, computer, automotive, appliance, semiconductor, and glass to metal seal industries.

At Sussex Wire, our people make the difference. We are passionate for our customers’ success, which we achieve through open collaboration, thoughtful and disciplined execution, a commitment to continuous improvement and a determination to win.

See our pages on LinkedIn.


  • Collaborative Engineering Design
  • Medical, Automotive, Micro-electronics, Defense Market Experience
  • World-Class Tool and Die Making
  • Forming to Finishing Integrated Lean Manufacturing
  • ISO 9001:2008 Certification
  • Production Runs up to 500+ Million Components
  • Component Tolerances to .0005"
  • Material Capabilities Inclusive of Specialty Alloys
  • Rich 40 Year History

February 11, 2014 - Hermetic electronic package design and assembly firms turn to Sussex Wire for six sigma process control for their most advanced component end condition and headed feature design and manufacturing.


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