| Item | Name | Data | Remark |
| 1 | Wire Diameter | 2-8mm | Soft wire |
| 4-6mm | Hard wire | ||
| 2 | Feeding speed | 40m/min | |
| 3 | Bend back distance | 800mm | |
| 4 | Inner tooling rotary degree | 0°-90°-180° | Automatic rotary |
| 5 | Outer tooling rotary degree | 360° | No limited |
| 6 | Machine head rotary degree | 360° | No limited |
| 7 | straightening roller | 17 group | |
| 8 | Axis | 3 axis | SANYO DENKI |
| 9 | Operation system | Yaqi | Domestic colorful controller |
| 10 | Feeding accuracy | ±0.1mm | 100mm |
| 11 | Bending accuracy | ±1° | |
| 12 | Voltage | 220V/3 phase / ground wire | Have 380V transformer |
| 13 | System storage memory | 2000 | |
| 14 | Automatic stop | Have automatic function | Material lack protection |
| 15 | Motor power | 13.5KW |
Bao Rui introduces the 3D CNC wire bending machine, a precision-driven solution engineered for modern manufacturing environments where wire bending automation, tube forming solutions, smart manufacturing trends, and CNC bending technology converge. Designed for manufacturers seeking consistent quality, higher throughput, and flexible production capability, the 3D CNC wire bending machine delivers advanced capabilities for a wide range of industries, including automotive, furniture, HVAC, medical devices, and consumer goods.
Product Features
The 3D CNC wire bending machine from Bao Rui integrates high-precision motion control with robust mechanics to achieve complex geometries and repeatable accuracy. Wire bending automation is achieved through a combination of servo-driven axes, closed-loop feedback systems, and an intuitive CNC controller that stores and executes complex bending programs. The machine supports multiple wire diameters and materials, enabling rapid changeover between jobs and minimizing downtime. A modular tooling system allows quick installation of mandrels, dies, and grippers, while automatic feed and cut modules streamline the production flow.
Advanced motion control powered by state-of-the-art CNC bending technology enables multi-plane bending and true 3D shaping without manual repositioning. The machine’s kinematic design reduces spring-back errors and compensates for material memory using adaptive correction algorithms. High-torque servo motors and precision ball screws guarantee smooth axis motion and high repeatability, which are essential for high-volume production runs that target minimal variance part-to-part.
Applications
The 3D CNC wire bending machine is optimized for applications requiring precision, repeatability, and the ability to produce complex geometries. In the automotive sector, the machine produces clips, brackets, and reinforcement wires with reliable dimensional control. For furniture manufacturing, it forms ergonomic frames, legs, and connectors with consistent surface finish and alignment. HVAC and refrigeration industries benefit from accurately formed tubing components and mounting hardware, while medical device manufacturers can produce small, intricate parts with tight tolerances. Consumer goods producers use the machine for items such as spring components, hangers, and display fixtures. Across these sectors, wire bending automation reduces manual labor, improves throughput, and enables consistent quality.
Innovative Elements
Bao Rui’s 3D CNC wire bending machine emphasizes innovation in both hardware and software. A built-in 3D simulation and verification system allows operators and process engineers to preview bending sequences and detect collisions or tooling interferences before physical production. This 3D simulation capability reduces trial-and-error during setup and supports the rapid commissioning of new parts, a critical advantage in fast-paced production environments that emphasize tube forming solutions and CNC bending technology.
The machine’s software suite supports parametric programming and the import of CAD models, enabling seamless transition from design to production. Adaptive process control algorithms analyze real-time feedback and adjust bending parameters to maintain tight tolerances. Intelligent diagnostics and predictive maintenance features monitor component wear and machine status, alerting maintenance teams before failures occur and contributing to uninterrupted production—an essential aspect of smart manufacturing trends.
Technical Advantages
Precision and repeatability are core technical advantages. The 3D CNC wire bending machine employs high-precision linear guides, hardened shafting, and closed-loop servo systems to maintain consistent bending angles and radii. The CNC bending technology includes interpolation across multiple axes, enabling continuous and synchronized movements for complex 3D shapes. Advanced chuck and gripper designs provide secure material handling, reducing slippage during high-force bends.
Material versatility is another strength. The machine accommodates various wire materials, including stainless steel, spring steel, copper alloys, and low-carbon steels. Its flexible tooling and feed systems allow quick adaptation to different cross-sections and profiles, offering end-users comprehensive tube forming solutions. Automatic cutter and end-formation options such as flattening or cold-forming heads are available to deliver ready-to-assemble parts directly off the machine.
Efficiency and integration capabilities position the Bao Rui 3D CNC wire bending machine as a central element in automated production lines. Integration with MES and factory-floor networks enables production scheduling, real-time monitoring, and data collection for continuous improvement initiatives tied to smart manufacturing trends. The machine’s compact footprint and modular design facilitate line expansion and flexible cell layouts, optimizing factory floor utilization and promoting scalable wire bending automation.
User Experience and Training
Bao Rui pairs the machine with a user-friendly HMI and programming environment tailored for both novice operators and experienced process engineers. The HMI features graphical setup screens, step-by-step tooling instructions, and built-in safety interlocks to accelerate safe startup and reduce setup time. Training programs and ongoing technical support back Bao Rui’s commitment to smooth adoption, ensuring customers leverage the full potential of the machine and its CNC bending technology.
Serviceability and Lifecycle Support
Designed for long-term serviceability, the 3D CNC wire bending machine incorporates accessible maintenance points and modular components that simplify repairs and upgrades. Bao Rui’s global parts and service network supports spare parts availability and remote troubleshooting, essential for minimizing downtime. Predictive diagnostics and recommended maintenance schedules, tied into the machine’s smart manufacturing trends capabilities, help customers maximize uptime and return on investment.
Customization and Turnkey Solutions
Bao Rui leverages its one-stop-shop capability to deliver customized tube forming solutions that align with customer production requirements. From initial concept and 3D simulation to prototype testing and full-line automation, Bao Rui provides end-to-end services. The company’s strong design team collaborates with clients to tailor tooling, automation interfaces, and part nesting strategies, ensuring the delivered solution meets throughput, accuracy, and cost targets.
Competitive Edge
Combining wire bending automation, CNC bending technology, and a focus on tube forming solutions, the Bao Rui 3D CNC wire bending machine stands out for its robust engineering, adaptive software, and integration-ready architecture. The machine’s ability to produce complex 3D geometries with high repeatability reduces downstream assembly challenges and scrap rates. Built-in simulation and predictive maintenance features align with smart manufacturing trends, enabling manufacturers to future-proof their operations.
The 408 wire bending machine combines wire feeding, head rotation and bending to form wire products in multiple directions and angles. It is suitable for automotive wire frames, seat structures, metal brackets and other complex wire components.
The rotary head supports 0–±180° bidirectional rotation, allowing flexible adjustment of the forming direction while reducing repeated wire rotation and manual repositioning.
The three axes coordinate wire feeding, head rotation and bending to handle multi-segment bending, continuous direction changes and combined angles for complex wire products.
The machine provides a wire feeding accuracy of ±0.05 mm, rotary accuracy of ±0.01° and bending accuracy of ±0.02°, helping reduce dimensional and angular variations in batch production.
5.Suitable for Different Wire Diameters and Product Sizes
The machine is suitable for Φ3–Φ8 mm wire and features an 800 mm working area for producing wire frames, brackets and other 3D wire components in different sizes.
To overcome the challenges of low production efficiency, high labor costs, and inconsistent spatial alignment in manual bending for complex 3D supermarket shelf hooks and wire mesh components, a leading European retail equipment manufacturer deployed Baorui Machinery's 3D CNC wire bending solution; featuring a 3-axis servo system and 360-degree rotating machine head, the system enables high-precision one-shot forming for intricate wire assemblies. This solution not only ensures every shelf accessory perfectly meets European high-quality aesthetic standards but also boosted overall production efficiency by over 300%, helping the client achieve significant cost reduction and operational excellence through automation in a competitive local market.
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