Our Products
Producers of Ferrous & Non-Ferrous Wires since 1983.
259 Center St.
Phillipsburg, NJ 08865, USA
BRAIDING
One of the many types of wire that we sell at Sinc is braided wire, or wire braid, which we simply make by braiding together separate strands of wire from braider bobbins.
What is Wire Braid?
A braid wire first starts out as a single end wire from almost any metal. We take single end wires and layer wind them flat on a bobbin that fits into a braiding machine. We can wind many ends but typically 2-11 ends are required. Sinc specializes in 28 Ga. (.0126 inch) to 44 Ga. (.002 inch) in singe end sizes to be braided. The bobbins are layer wound so when payed off in the braider they come off as a flat ribbon of single end wires.
Note that our braided wire is different than our stranded wire, which features strands of wire that we have twisted, not braided.
Braided wire is a great choice if some or all of your priorities include: breakage resistance, strength, flexibility, conductivity and/or sound absorption. Braided wire products are especially strong and conductive in comparison to regular solid wire products.
Our Braided Wire
We get requests for braided wire from customers in a myriad of industries, including aerospace, defense, mechanics, electronics and electromagnetic shielding, and construction.
There are many types of braiding machines and Sinc Inc. has machines which can hold 12 to 48 bobbins in a braider. The bobbins are loaded onto the carriers, which hold the bobbin and then rotate in a circular pattern around a core or just as braid to be flattened or left as tubular braid. Some machines rotate differently, some have half the machine rotating one way while the other half rotates the opposite direction. Other braiders move bobbins in and out of each other on a track system, these are called maypole braiders.
To cater to the wide-ranging requirements of our customers, Sinc uses over 80 different braiders in 12, 16, 24 and 48 carrier configurations, and can custom-build braid per customer requirements. Sinc uses two different types of braiders which allows us to make wire braid in tubular, flat, or custom shapes, from wire sizes typically ranging between 28 gauge and 44 gauge in wire diameter.
We offer our braided wire products in countless different lengths, widths, and strengths. Note that the more wires, the stronger the rope.
In addition to providing you with new braided wire products, we can also improve on cables you already own by braiding wire directly over them. This is a great choice for you if you’re looking to improve the abrasion resistance of your cable or to create a shielding effect.
We most manufacture our wire braid from pure nickel, stainless steel, copper both plated and bare, copper clad steel and we also accept requests for wire braid made from other materials. We offer custom small diameter and miniature wire options.
Cleaning Braid
Sinc has a high-end cleaning machine that can clean the braid so the wire is bright and has no residue. This is highly sought after as many customers now demand clean wire.
Getting Started
To help you determine the right wire braid configuration for you, a member of our development staff will discuss your custom application details with you.
Once they have enough information, our development team will design a prototype and produce a sample that you can review. Our team will then follow up with you to discuss the braided wire performance. They take into consideration all of your notes, and make any necessary changes.
After that, our sales team will contact you with price quotation and an estimated delivery date. Only after they’ve confirmed that you are on the same page our development staff will send your wire braid request on to our manufacturing staff.
Before delivering your braided products to you, our team puts them through a series of quality tests. After that, we ship your products to you.
We’re excited to work with you! Reach out to us today to get started.
Our goal is to innovate with you via our unique partnership with Jersey Strand & Cable, Inc.
We would love to connect! To collaborate with our team, or to learn more about our standard and custom wire braid products, reach out to us via phone or email today.
STRANDING
Another popular type of wire rope that we manufacture is stranded wire. We create stranded wire, which we sometimes call wire strand, by stranding together individual wire filaments into strands, and then wrapping them helically around a core to make rope.
So, stranded wire is made up of: wire filaments, strands, and a core. We define strands as multiple wires that are laid together helically and symmetrically arranged with uniform pitch or lay.
Wire strand has a lot to offer. It is flexible, strong, great for support and lifting mechanical loads, and it holds up well in the face of tension, vibration, and movement. Made from the right metals, wire strand can be a great conductor of electricity, and useful in telecommunications.
Wire strand is also highly customizable. For example, stranded wire changes per the thickness of its strands. In general, the smaller the wire filament diameter, the more flexible the stranded wire. Meanwhile, the thicker the wire filament diameter, the stiffer the stranded wire.
Some of the many industries that rely on our stranded wire products include: aerospace, electronics, defense, automotive, chemical, communications, healthcare, and security.
We offer stranded wire with a wide range of strand counts, wires per strand counts, pitches, lays, lengths, widths, and materials.
We offer stranded wire in different joining arrangements including: concentric stranding, unilay stranding, rope lay, and more.
Our size capabilities range from 0.003’ TO 1/8” finished strand diameter.
Learn more by reaching out to our customer service team.
Some of the stranded wire we most often manufacture include:
- 1 x 3 (1 set of 3 wires bundled together)
- 1 x 7 (6 wires wrapped around 1 center wire)
- 1 x 19 (12 wires laid around 1 center 1 x 7 strand)
- 3 x 7 (3 sets of 1 x 7 strands bundled together)
- 7 x 3 (6 sets of 1 x 3 strands cabled around a 1 x 3 center strand)
- 7 x 7 (6 sets of 1 x 7 strands cabled around 1 center 1 x 7 strand)
- 7 x 19 (6 1 x 19 strands cabled around 1 center 1 x 19 strand)
Every wire strand configuration offers something different. For example, small diameter stranded wire, like 1 x 3 stranded wire, is highly strong for its diameter. In contrast, other stranded wire configurations, like 1 x 7 or 1 x 19 stranded wire ropes, have more flexibility. Wire strand products like 1×3, 1×7 and 1×19 are perfect for push-pull applications.
Materials used to make stranded wire include:
- Stainless Steel (corrosion resistant, strong, economical)
- High Carbon Steel (extremely strong, wear resistant)
- Brass Plated Steel (strong, perfect for applications that require rubber adhesion)
- Copper Clad Steel (strong, ideal for applications that require strong and conductive materials)
- Copper Alloy (perfect for electronic applications)
- Brass Alloy (aesthetically pleasing, strong, durable)
- Bronze Alloy (aesthetically pleasing, strong, durable)
- Nickel Alloy (perfect in high temperature environments and highly corrosive environments)
- Titanium Alloy (ideal in applications requiring light strength, biocompatibility, and/or specific corrosion resistance)
- Aluminum Alloy (works well as lightweight, low-density electrical conductor)
To find the perfect wire strand configuration for your application, contact us with your application specifications today. We look forward to working with you.
SINGLE END
In the wire and cable industry, single end refers to one individual wire or stand being processed, handled, wound or tested independently, as opposed to multiple wires running together. It is the basic unit before stranding, cabling, bobbin winding or braiding.
Before wires are twisted together, each individual wire is a “single end.” For example, a 7-strand conductor starts with 7 single ends.
Spark testing, diameter measurement, elongation test, etc., can be done on a single end before it becomes part of a cable. A single end payoff feeds only one wire into a process, compared to a multi-end payoff that handles multiple wires simultaneously.
ULTRA FINE WIRE
Ultra-fine wire refers to wires with an extremely small diameter, smaller than .004 inch down to .001 inch. These wires are so thin that they are often called micro-wire, fine gauge wire, or extra-fine wire.
They are highly flexible due to their thinness. They have high conductivity for their cross-section (if copper or silver). They also have high surface area to volume ratio (important for plating and coating. They are easily damaged if not handled carefully.
Ultra-fine wire is used where small size and high precision are critical:
- Electronics and semiconductors: wire bonding, PCB connections and coil windings
- Medial Devices: catheters, pacemaker leads, stents, and micro-electrodes
- Aerospace: instrumentation wiring in compact or high-performance assemblies
- Sensors & Micro Coils: micro-transfers, inductors, or solenoids
- Precision Motors: tiny coils in motors for drones, watches, or robotics
Producing ultra-fine wire requires advanced processes:
Drawing:
- Multi-stage wire drawing through extremely fine dies
- Often includes intermediate annealing to prevent breakage.
Annealing/ Heat Treatment:
- Relieves stress from drawing
- Ensures flexibility
Handling & Spooling:
- Requires single-end winding with precision tension control
- Often respooled onto micro-bobbins to prevent kinking
Coating/Plating:
- May be plated with tin, silver, or gold for corrosion resistance or solderability
BOBBIN WINDING
Bobbins are small spools that fit into braiding machines. There are different types of bobbins including Wardwell and NEB. Metals used are varied: copper, stainless steel, nickel alloys, silver plated copper, nickel plated copper, copper clad steel, galvanized steel and may more.
We bobbin wind in sizes down to .0016 and finer on some metals. We do 1-12 ends on a bobbin. All material is layer wound and put in boxes the hold 16 or 24 bobbins.
We follow all the appropriate ASTM’s.
RESPOOLING
Respooling is the process of rewinding wire, strand, or cable from one spool, reel, or bobbin onto another. It is typically performed after primary manufacturing but before shipping, inspection, or secondary processing. It is essentially a controlled transfer operation that improves product presentation, quality, or usability for the next stage of production.
Respooling uses:
Changing Package size or type:
Improving Winding Quality:
Measuring & Confirming Length:
The Process:
Payoff:
Tension Control:
Inspection Zone:
Traverse System:
Benefits:
VIEW THE METALS & MATERIALS WE USE
< BACK TO PRODUCTS
Respooling is the process of rewinding wire, strand, or cable from one spool, reel, or bobbin onto another. It is typically performed after primary manufacturing but before shipping, inspection, or secondary processing. It is essentially a controlled transfer operation that improves product presentation, quality, or usability for the next stage of production.
Respooling uses:
Changing Package size or type:
- Moving wire to a new spool size (smaller, larger, or standardized)
- Switching from metal reels to plastic, cardboard, or customer-specified packaging
Improving Winding Quality:
- Creating clean level-wound packages for better payoff
Measuring & Confirming Length:
- Footage counters – this ensures the customer receives exact lengths and quality
The Process:
Payoff:
- Wire is unwound from the original spool or reel
Tension Control:
- Brakes or electronic tension systems prevent stretching, twisting, or sudden jerks
Inspection Zone:
- Operators visually inspect the wire; some lines include cameras or spark tester.
Traverse System:
- Guides the wire onto the new spool with controlled side-to-side movement
Benefits:
- Clean, consistent packaging
- Improved quality control
- Low scrap and fewer customer complaints
VIEW THE METALS & MATERIALS WE USE
< BACK TO PRODUCTS
WIRE WRAPPING
Wire wrapping on a specialized proprietary machine able to wrap wire around other substrates. Helical winding is a method of winding wire in a continuous spiral or helical pattern around a core.
HEAT TREATMENT
Heat treatment is the controlled heating and cooling of metal wire to change its mechanical properties, such as flexibility, hardness, strength and conductivity.
Uses:
Soften the wire (annealing)
- Easier to bend
- Less likely to crack
- Better crimping and termination
Relieve internal stresses:
Drawing, spooling, and straightening create stress in the metal. Heat treatment removes these stresses, stabilizing the wire so it behave predictably during the future processes
Improve surface quality:
- Smoother surfaces
- Fewer micro-cracks
- Better plating or insulation adhesion
Types of Heat Treatment:
Annealing (most common)
- Temperature controlled heating to soften wire.
- Strand annealer multi tube.
Stress Relieving:
- Heats wire just enough to remove internal stress without significantly softening it.
- Stainless steel wires, spring wire, and wire that needs controlled stiffness
Normalizing:
Heats steel wire above its critical temperature, then air cools it.
- High-carbon wire
- Armoring wire
- Mechanical cable
The typical sequence of heat treatment in the production line:
- Intermediate drawing
- Final drawing
- Heat treatment (mostly annealing)
- Cleaning/Coating
- Stranding/Cabling
Benefits:
- Reduced breakage during stranding
- Better extrusion performance
- Improved conductor flexibility
- Smoother final product
- Higher electrical performance
- Less scrap and downtime
CUT LENGTHS
Cut lengths refer to wire, cable, or tubing that has been measured and cut to a specific length, rather than shipped on a reel, bobbin, or spool.
It is a value-added service for customers who need ready-to-use segments.
We custom cut lengths to your specifications.
CLEAN WIRE
Ultrasonic Clean Machine:
Powerful large ultrasonic clean machine. We can clean single end, braid and strand to fine sizes. All the wire used for the Eisenhower tapestry was cleaned on the clean machine.
WIRE SIZES
We offer sizes down to .001. We braid, wire wrap, respool, bobbin wind, and supply single end. Our sister company, Jersey Stand and Cable, can strand all metals and to ultra fine strands.