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Precise Wire Bending Machine

Open-source wire bending CNC machine for wires at 1mm and less in diameter.

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I build sculptures out of brass wires and since I hate repeating creating same part over and over again I decided to build a wire bending CNC machine that would do the job for me. So far it is still an early prototype but looks promising! The goal is to build a machine that has most of the parts 3D printer or easy to get so everybody can build it at home.

Detailed instructions how to build one can be found here https://www.instructables.com/id/Spring-Making-Wire-Bending-Machine/

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tazmahv wrote 08/24/2019 at 14:07 point

hola desde el primer día que vi la máquina me sorprendió
que ya tengo todos los componentes para armar bender
dudas ¿puedes trabajar con mach3 ???
cuál sería la forma más fácil de operar una máquina de doblar para un novato
Gracias

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elizabeth.a.greene wrote 07/25/2019 at 22:38 point

This is lovely, and I very much want to build one.  

Questions!
Are you sending it G-Code to make the pattern, or some other control language?
Is there a wirebender CAD program?
Have you considered adding a rotary axis to make more complex forms?


Thanks!

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Jiří Praus wrote 07/31/2019 at 06:55 point

Yeas, G-Code. I am using cnc.js and GRBL firmware.

I wanted to create the simplest version and improve. So yes I want to make more complex shapes ;)

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Jo Verbeeck wrote 07/24/2019 at 19:55 point

any chance this could make the worlds smallest solenoid? I would be interested in <100um wire and eventually much less.

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Jiří Praus wrote 07/31/2019 at 06:56 point

That would require all parts to scale down (feeding gear, straightener gears, bending head). But I don't see a trouble in that :)

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Dylan Brophy wrote 07/18/2019 at 17:51 point

Perhaps this could be modified to make wire sculpures and make solenoids/transformers, I have actually experimented with machines to make the latter myself (because I don't want to buy solenoids/transformers nor wind wire all day)

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Jiří Praus wrote 07/21/2019 at 08:43 point

It depends whether you can build them with .8mm wire. Isn't that too much?

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Dylan Brophy wrote 07/21/2019 at 15:52 point

good point.  But like I said, may need modification. Just a thought though

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ekaggrat singh kalsi wrote 07/18/2019 at 03:23 point

how do you get the wire to form a spring by bending in 3d? should it just continue bending in the same plane and overlap the previous curve? great work ! i am also building a modular wire bender but got stalled because i don't have a reliable feeder. also eventually u will need to add a servo to raise and drop the bending pin if you want to bend in two direction ( left and right )

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Jiří Praus wrote 07/21/2019 at 08:41 point

The pitch is defined by the thickness of the bending plate. The bending plate has a sharp edge to make the wire slip on its top rather than stuck on its edge. But the springs are not the target use case.

Exactly, I want to make the bending head retractable to be able to bend in two directions.

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Starhawk wrote 07/18/2019 at 00:55 point

For some reason, a wire sculpture of Bender from "Futurama" does not appear to exist on the Internet. Might I suggest that you should use your wire bender to make a Wire Bender...? ;)

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Jiří Praus wrote 07/21/2019 at 08:39 point

Good idea :D

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Involute wrote 07/17/2019 at 22:26 point

Last year I spent some time developing a machine that will cut insulated electrical wire to various lengths.  The main stumbling block was the feed mechanism which, like yours, kept slipping.  I used a similar approach of pinching the wire between a stepper-driven, toothed roller and a bearing, but couldn't get it to work reliably.  Have you solved the problem in your version 3?

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Jan wrote 07/19/2019 at 05:16 point

Have you looked at the recent version? He uses a grooved feeding roller which prevents slipping quite well. 

That may be not practical when using many different wire diameters like in your approach but it works well here... 

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Jiří Praus wrote 07/21/2019 at 08:39 point

This particular feeding roller I user has grove for 1mm and .8mm wires. But many other for different diameters can be found and are simple exchangeable. So it would not be problem to use various wires.

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siddacious wrote 07/17/2019 at 17:16 point

*ahem*

.

.

.

THIS IS SO COOOOOOOOOOOOOOL!

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dschwant wrote 07/17/2019 at 17:15 point

Your work reminded me of this - https://youtu.be/HPQbKTJPsU4

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Jiří Praus wrote 07/21/2019 at 08:37 point

This was source of inspiration as well. But I wanted to make it precise.

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see3d wrote 07/17/2019 at 16:49 point

Love this simple design.  I am often re-bending paperclips into different spring shapes.  I have had it in the back of my mind that I would like to automate it.  Right now, I 3D print bending fixtures to make repeated parts.

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Jiří Praus wrote 07/21/2019 at 08:35 point

Yeah, I was thinking of that as well. But this was much more challenging :)

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salmanisheikh wrote 07/17/2019 at 16:32 point

Is this project going to be open-sourced?

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Jiří Praus wrote 07/21/2019 at 08:37 point

It already is under CC BY-NC-SA 4.0 license

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Tom Nardi wrote 07/04/2019 at 20:45 point

Fantastic design, I could watch this thing go all day.

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Jan wrote 07/05/2019 at 04:45 point

Then give the video Iinked below a try :) 

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Jan wrote 07/04/2019 at 08:31 point

Sweet. How's the rotation done around the wires' axis?

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Jiří Praus wrote 07/04/2019 at 18:34 point

Currently, it is an unwanted rotation caused by drive gears. However, I've added the straightening phase and it holds the wire at a still angle. But now the problem is the drive gear which has low adhesion so I am upgrading that one :)

When this 2D bender is done I want to experiment with second axis to create 3D bender.

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Jan wrote 07/04/2019 at 18:48 point

Nice, sounds like a good plan! See https://youtu.be/5QjVeH2Z57E for your wire bending porn needs :D 

No, srsly watch that short film if you haven't yet. It's mesmerizing to say the least... 

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Tillo wrote 07/05/2019 at 12:06 point

@Jan that bending porn is perfect. They even colorgraded it to an amazing style. 

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RichSr40 wrote 07/17/2019 at 20:30 point

check thé 90 degree rotation at thé start( where thé wire enters) and thé coil size determins latéral motion.  There are other factors innvolved as well.  But that la à start :) 

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