Special-Shaped Dies
Beyond round. We engineer complex profile dies with sub-micron accuracy for EV motors, electronics, and aerospace components.
The Art of Profile Drawing
Drawing non-round wire introduces complex stress concentrations that don't exist in round dies. The material flows faster in the center of the die than at the corners, which can lead to cracking or twisting.
Titan solves this with Asymmetrical Bearing Design. We vary the bearing length across the profile—shorter at the corners, longer on the flats—to equalize drag forces and ensure uniform material velocity.
Precision Manufacturing
We utilize state-of-the-art Wire EDM (Electrical Discharge Machining) and Profile Grinding technology to produce shapes that were once considered impossible.
- Corner Radii: As small as 0.02mm for sharp-edged profiles.
- Surface Finish: Profile bearings polished to Ra < 0.1μm.
- Materials: Available in Tungsten Carbide and PCD (for simple shapes).
Capabilities
Custom Geometry
We accept .DXF and .DWG files to manufacture dies directly from your CAD data.
Tolerances
Profile accuracy maintained to within ±0.002mm.
Digital Validation
3D scanning of finished dies ensures the profile matches your digital twin.
"The rectangular dies for our flat copper wire line have been running for 6 months with zero dimensional drift. The corner consistency is excellent."
- Manufacturing Engineer, E-Mobility Motors
Profile Solutions
Flat & Rectangular Dies
For magnet wire and EV motor windings. Precise corner radii control to prevent insulation cracking.
Hexagonal & Square Dies
High-impact tungsten carbide dies for drawing connector pins and aerospace fasteners.
Custom Profile Dies
Complex asymmetrical shapes (Z-wire, Trolley wire) manufactured directly from your CAD drawings using high-precision Wire EDM.
Have a challenging shape?
Upload your drawing. Our engineers will perform a feasibility analysis and recommend the optimal material and reduction steps.