DIY Wire Bender Gets Wires All Bent Into Shape


It’s been a while since we’ve shown a DIY wire bending machine, and [How To Mechatronics] has come up with an elegant design with easy construction through the use of 3D-printed parts which handle most of the inherent complexity. This one also has a Z-axis so that you can produce 3D wire shapes. And as with all wire bending machines, it’s fun to watch it in action, which you can do in the video below along with seeing the step-by-step construction.

One nice feature is that he’s included a limit switch for automatically positioning the Z-axis when you first turn it on. It also uses a single 12 volt supply for all the motors, and the Arduino that acts as the brains. The 5 volts for the one servo motor is converted from 12 using an LM7805 voltage regulator. He’s also done a nice job packaging the Arduino, stepper motor driver boards, and the discrete components all onto a single custom surface mount PCB.

Wire straightener and feeder
Wire straightener and feeder

The bender isn’t without some issues though, such as that there’s no automatic method for giving it bending instructions. You can write code for the steps into an Arduino sketch, which is really just a lot of copy and paste, and he’s also provided a manual mode. In manual mode, you give it simple commands from a serial terminal. However, it would be only one step more to get those same commands from a file, or perhaps even convert from G-code or some other format.

Another issue is that the wire straightener puts too much tension on the wire, preventing the feeder from being able to pull the wire along. One solution is to feed it pre-straightened wire, not too much to ask for since it’s really the bending we’re after. But fixing this problem outright could be as simple as changing two parts. For the feeder, the wire is pulled between copper pipe and a flat steel bearing, and we can’t help wondering whether perhaps replacing them with a knurled cylinder and a grooved one would work as the people at [PENSA] did with their DIWire which we wrote about back in 2012. Sadly, the blog entries we linked to no longer work but a search shows that their instructable is still up if you want to check out their feeder parts.

As for the applications, we can think of sculpting, fractal antennas, tracks for marble machines, and really anything which could use a wireframe for its structure. Ideas anyone?



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