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Sussex Wire is a world leader in the design and manufacture of micro-precision wire forged components for critical applications

About Sussex Wire



Headquartered in Easton, Pennsylvania, Sussex Wire specializes in the design, manufacturing and distribution of highly-engineered, specialty metal parts and components. The Company, founded in 1973, utilizes cold-forming technology to form metal wire and specialty alloys at room temperatures into highly engineered precision, micro-miniature components faster in a more cost-effective manner than traditional machining, stamping, metal injection molding and casting methodologies. Sussex Wire has designed and engineered processes that improve product quality and differentiates the Company’s competitive position. The Company serves a variety of global blue chip customers who operate in the medical, electronics, connectors, computer, automobile, transportation, appliance, semiconductors, and glass to metal seal industries.

Sussex Wire is one of a very few companies in the world that can do miniature, precision, geometrically complex, cold forming of parts ranging from 10 million to over 1 billion per year. The Company has the ability to manufacture and form symmetrical and asymmetrical components from wire diameters of 0.0035’’ to 0.250’’. While Sussex Wire is capable of manufacturing components using larger than 0.250” diameter wire, it typically focuses on micro-miniature components. The Company is ISO 9001-2008 certified and ITAR (International Traffic in Arms Regulations) compliant. In addition, the Company routinely passes rigorous quality audits from FDA certified customers.

Sussex Wire owns and operates a wide variety of machines specially designed for the cold-forming and cold-heading process, including computerized cold-forming machines, four-slide machines, rolling, forming, tapping, and sink and wire electrical discharge machines. In addition, the Company has custom-built certain machinery to combine certain cold-heading and wire-forming processes to meet customer specifications. Another competitive advantage is Sussex Wire’s ability to work with a variety of different metals, including exotic metals, expansion alloys, nickel alloys, kovar, cobalt, precious metals (gold, silver, platinum, and palladium), copper, steel, brass and stainless steel. Sussex Wire has a complete tool room with state of the art equipment (CNC sinker EDM, CNC wire EDM), plus conventional metal working machine tools oriented towards small diameter work. The Company also has CAD and CAD-simulation capabilities which increases successful set-ups and decreases lead times because troubleshooting can be assessed prior to production.


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