Sussex Wire's Metal Forming Simulation



Sussex Wire employs the most advanced component, die and tool formation simulation software analyzing the three-dimensional (3D) flow of complex metal forming processes. Our part design and soft tooling is a practical and efficient approach to predict the material flow in forming operations without the cost and delay of shop trials. 3D simulation used for closed and open die forging, rolling, extrusion, heading, drawing, cogging, compaction and upsetting affords clients the benefit of low cost, rapid prototyping for critical dimension tight tolerance precision metal parts produced from a variety of metals; including exotic metals, expansion alloys, nickel alloys, kovar, cobalt, precious metals (gold, silver, platinum, and palladium), copper, steel, brass and stainless steel.


Our 3D part simulation capabilities enables collaborative engineering design with client NPD teams finding the best mechanical, electrical and fluid management component solution. Clients receive real-time visual representation of the efficacy and cost effective benefits in converting expensive and poor tensile strength properties latent to screw machine, milling and machining center, stamped, drawn and swaged manufacturing processes. Our CAD / CAM-simulation approach to tool, die and component formation mitigates shop floor trial and error methodology. Sussex Wire’s simulation approach is capable of predicting large deformation material flow and thermal behavior with astonishing precision.



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