Aerospace, Defense and Commercial Hermetic Device Contractors Depend on Sussex Wire Components for Six Sigma Performance

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. Sussex Wire, a global design and manufacturing company of precision micro metal components headquartered in Easton, Pennsylvania, employs proprietary manufacturing technologies to produce component radius, edge break and shape control tolerances to +/- 0.0005” from Copper Core Steels and Alloys, Stainless, Kovar, 52 & 42 Alloy, Inconel, Tantalum, Molybdenum, Hastelloy and Precious Metals such as Platinum, Palladium, Silver.

Sussex Wire’s manufacturing and design engineers developed tooling, machine technology and cellular work centers to produce Glass-to-Metal-Seal component features to tolerances often beyond the capabilities of traditional machining or stamping parts manufacturers. “Our hermetic package component customers depend on our process design and six sigma quality system to keep their customers’ missiles on target, marine-based communications 100% reliable, energetics failsafe and to mil-spec standards”, commented Donna Warman, Sussex Wire’s Operations Manager.

Sussex Wire utilizes cold-forming and roll-forming technologies to shape metal wire and specialty alloys at room temperatures into highly engineered, precision, micro-miniature components faster and in a more cost-effective manner than traditional machining, stamping, metal injection molding and casting methods can. The Company serves global blue chip customers who operate in the medical, electronics, connectors, computer, automobile, transportation, appliance, semiconductors, and glass to metal seal industries. Dozens of examples of custom parts are illustrated on the Company's website,

About Sussex Wire, Inc.
Sussex Wire is one of a very few companies in the world that can manufacturer miniature, precision, geometrically complex, cold forming of parts in quantities 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’’. The Company is ISO 9001-2008 certified.


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