A bigger, more capable and more accurate brother for the kickstarter famous D.I.Wire Plus, this benchtop CNC machine bends wire from 0.5 to 5mm diameter in stainless. Swappable feed wheels and bend mandrels allow a range of applications, and CAM interpretation of 2d curves into G-code commands speeds programming new shapes. I managed a team of engineers and an industrial designer on this project at Pensa, from initial sketches to design and production of custom machined, multi-axis 360° spinning mechanisms. Design development through several revisions, electromechanics, prototyping, GD&T and run-testing was performed in our lab.
Above: D.I.Wire is configurable with a variety of tooling, straightener, and calibration routines for various materials. Orthodontic labs are a major market for D.I.Wire Pro, automating portions of a process done by hand today.
Below: Solidworks model with sheet metal chassis, machined feed and bend mechanisms, drivetrain and motion control system. At least 5 design iterations led to the nearly complete machine assembly shown here.
