How Wire is Made

by Judy Ellis

The term "wire wrapping" is a bit like "suntan."

When you get a suntan (soon, people!), you show off your bronzed skin - it's all about the tan. As for the sun's role? Well, it's there somewhere.

So it is with wire wrapping. Who, really, thinks about the wire? (OK, except for you home metallurgists getting ready to email me.) When someone admires your beautifully wrapped pendent, they're not thinking: "Where did that wire come from?"

It seems that wire, like the sun, is taken for granted. So, we wanted to correct that oversight, give appreciation where it's due.

After a bit of research, I've gained more respect for the lowly paper clip, and particularly for the fine wire we carry here at Wire-Sculpture.

I've also learned that I can make (someday!) my own wire - yep, I didn't know that was even possible.

How Wire was Made - In the Beginning

Wire dates back to Egypt's 2nd Dynasty, around 2600 BC.

Its purpose was jewelry and chains.

Ancient Egyptians pounded metal into sheets, then sliced them into strips.

They twisted or rolled the strips to create seamed wire.

The Etruscans, absorbed by ancient Romans, made short wire lengths using anvil, fire, and hammer.

Draw Plates Changed the Game

Early wire-making methods stayed advanced until medieval times.

An English craftsman invented pulling metal through a small hole in a drawplate.

This wire drawing process is still used today.

Medieval people used wire for practical items, like wool-carding brushes.

Wire returned to decorative uses, such as brooches and necklaces, in the Victorian era.

Now Wire Mills are Highly Mechanized

Wire-making has evolved into a highly mechanized industry.

The process still follows basic steps from centuries ago, with electricity replacing brute strength.

Strips of metal are pounded or rolled into shape.

They are pulled through a funnel-like hole in a cast-iron or diamond drawplate.

As wire is drawn through, its diameter reduces and length increases.

Progressive smaller openings make it thinner.

Round wire is most common.

Special drawplates create half-round and square shapes.

Wire reduces in increments of about one-tenth millimeter.

Final hole size sets the gauge.

To start, file or pound the wire end to a point.

Attach pincers and pull through using a winch or tension pulley.

Before electricity, laborers grunted and sweated, cranking by hand.

This technique persists in home metal shops today.

Yes, the grunting and sweating still happen!

Wire Hardness

Working with metal hardens it.

You've likely hammered jewelry to prevent bending.

Wire temper relates directly to the drawing process.

Wire hardness was once measured from 0 to 4.

Softest wire (0) passed through the die once.

Hardness 2 meant twice, and 4 meant five or more times.

Each pass stiffened and strengthened it.

Today, wire is sold as dead soft, half-hard, or full hard.

Dead soft equals hardness 0.

Half-hard equals 2.

Full hard equals 4.

Copper jewelry wire passes through 10 or more drawplates.

It anneals every few stages to soften.

Telephone wire draws up to 20 times while hot.

Modern artisans use these steps with silver and gold.

Check this link for a craftsman's step-by-step process.

Now I appreciate wire more.

Time to step outside for a suntan!

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