Shape Dies

These dies are essential for producing specialized wire profiles that standard round dies cannot achieve, enabling manufacturers to meet demanding requirements for form, function, and performance in modern applications.

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Core Design and Materials

At the heart of Relink Shape Dies is a high-performance polycrystalline diamond (PCD) core, renowned for its exceptional hardness (up to 10,000 HV), superior thermal conductivity, and outstanding wear resistance. For applications where cost optimization is prioritized without sacrificing too much durability, we also offer tungsten carbide (WC) variants. Both options are encased in robust stainless steel housings to ensure corrosion resistance, structural integrity, and seamless compatibility with high-pressure drawing systems.

This material selection allows Relink Shape Dies to deliver dramatically extended service life—typically 50–100 times longer than conventional carbide dies, and in many cases up to 200 times under optimized conditions—while maintaining consistent profile geometry throughout millions of meters of wire production.

Supported Profiles and Customization

Relink Shape Dies support a broad spectrum of standard and bespoke geometries to suit diverse production needs:

• Standard shapes: rectangles, squares, hexagons, octagons, ovals, triangles, trapezoids, flats, and half-rounds.

• Custom profiles: Fully tailored designs including D-shapes, teardrops, stars, irregular polygons, gear-like contours, or any client-specified cross-section based on detailed drawings, CAD files, or physical samples.

Our engineering team uses advanced CNC machining, wire EDM technology, and optical profilometry to replicate exact specifications with micron-level precision. Whether transitioning from round to rectangular wire in a multi-pass sequence or creating complex profiles for specialized conductors, Relink provides end-to-end customization—from initial design consultation to rapid prototyping and production scaling.

Key Performance Advantages

Relink Shape Dies excel in high-speed, high-volume environments thanks to several critical benefits:

• Superior Wear Resistance & Uniform Wear: PCD’s low friction coefficient and high thermal stability minimize abrasive wear, prevent uneven die enlargement, and ensure long-term dimensional stability—resulting in fewer profile deviations and reduced scrap rates.

• Exceptional Surface Finish: Achieved Ra values as low as 0.05–0.1 μm on the drawn wire, often eliminating or minimizing downstream polishing steps and improving conductor performance in electrical applications.

• High-Speed Compatibility: Supports drawing speeds up to 2,000 m/min with excellent heat dissipation, enabling faster throughput, lower energy consumption per meter, and reduced production downtime.

• Versatile Material Handling: Optimized for non-ferrous metals like copper and aluminum (ideal for PCD), as well as harder alloys, stainless steel, and specialty wires (WC options provide balanced toughness for abrasive or high-strength materials).

• Pressure & Non-Pressure Flexibility: Engineered for both lubricated pressure-assisted drawing (enhancing flow and finish) and dry/non-pressure setups, making them adaptable to various machine configurations.

Industry Applications & Value Proposition

Relink Shape Dies are widely deployed across industries that demand precise, non-round wire geometries:

• Automotive: Flat or rectangular conductors for wiring harnesses, EV battery busbars, and high-current cables.

• Electronics & Telecommunications: Precision profiles for enameled magnet wire, connectors, and high-frequency cables.

• Aerospace & Defense: Lightweight alloy wires with custom shapes for structural or conductive components.

• Renewable Energy: Photovoltaic ribbon wire, solar panel interconnects, and wind turbine cabling.

• Industrial Manufacturing: Shaped wires for springs, fasteners, filters, and architectural applications.

By choosing Relink Shape Dies, manufacturers gain measurable ROI through:

• Extended tool life that slashes replacement frequency and inventory costs.

• Consistent tolerances that improve downstream processing yield.

• Reduced material waste and energy use for more sustainable operations.

• Faster lead times from our Taiwan-based production facility, with global shipping support.

Relink Shape Dies combine cutting-edge PCD technology, rigorous quality control (ISO 9001 certified), and customer-centric customization to deliver reliable, high-performance solutions that help wire and cable producers stay competitive in fast-evolving markets.

Uniform Polishing

Provides consistent high-quality finishes.

Reduced Maintenance

Minimal repairs and reconditioning required, maximizing uptime.

Low Friction

Ensures smooth wire drawing without premature die wear.

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