WAFIOS Machinery Corp

• Booth: D41948

 Press Releases

• Simple Setup for Rapid Wire Bending Processes New Developments among WAFIO (May 14, 2025)
  WAFIOS celebrates diversity – among people and machines. Its wire bending machines offer flexible bending solutions for round or profiled wire as well as for tubes. Modular tool solutions, an assisted setup procedure and a new insulation stripping device are just a few of the many new developments when it comes to wire bending.  Turbulent times bring uncertainty for manufacturers and consumers alike. Yet one thing is certain: WAFIOS machines are a safe investment in the future. The built-to- last machines unite the highest quality standards, innovative developments and increased productivity. The WAFIOS product portfolio extends from wire straightening and cutting machines to chain manufacturing, spring and wire bending machines and is rooted in many years of experience. For manufacturers seeking maximum precision and performance, the High-Performance series are the perfect choice. While for economical production ranging from prototypes to high volumes, the Performance machines are ideal. Defined packages of supplementary equipment round out the optimized basic scope of equipment.  Increase speed with the HighSpeed machines Providing a boost in terms of both speed and performance, the highly dynamic drives of the HighSpeed machines in the BM series raise production to a new level. The powerful machines epitomize flexible production of highly complex bent wire parts, focusing on large volumes and the highest quality standards. Thanks to iQsmartbend, which is already included in the basic price of the BM HS series as a 5-year license, the CNC high-end wire bending machines achieve up to 40 percent higher output, depending on the workpiece produced, compared with the predecessor machines. The iQ function optimizes bent parts fully automatically in terms of their vibrations in the bending process; the reduced vibrations accelerate the bending process and significantly increase the output achieved.  Yet when it comes to manufacturing various bent parts, it is more than simply speed that plays a role.  Straighten with ease Each new wire coil involves a new setup process. The straightening devices are set manually, and the process mainly depends on the experience of the operating personnel. Straightening results and the time required therefore vary from operator to operator. Modern software such as iQplug&straight cancels out these variations. The AI-based iQplug&straight software guides the operator systematically through the optimum setup of the straightening devices.  The iQ function measures a straightened rod with the aid of a highly sensitive measuring assembly outside the machine. The software’s artificial intelligence suggests optimized settings for the straightening rollers, making time-consuming straightening settings a thing of the past.   Modular tool system: always the right bending radius A straightened wire is not the end of the story. Until now, new, adapted bending tools have been needed to deal with new bending geometries or new wire dimensions. Designing and manufacturing these tools costs time and money. The new modular tool system for High-Performance machines solves this problem.  The patented system consists of a toolbox which can be used to put together a bending tool with two bending radii within just a few minutes for the entire operating range of the machine. There is no design or manufacturing stage. Developed specially for the MBS tool, the simplified tool input in the WAFIOS Programming System (WPS 3.2 EasyWay) enables the required process data and characteristics to be created quickly and automatically. The process is based on minimal inputs and can be completed in next to no time. As a result, a new bending tool can be created with ease, or the existing tool configuration can be adapted rapidly.  The bending system is available for wire diameters from 2 to 13 mm and is compatible with the BM and BMU machines. Depending on the wire material and quality requirements, the bending pins are available with or without coating or as a roller.  

• The Right Solution for Any Type of Busbar (May 14, 2025)
  Rising demand for mechanical insulation stripping of busbars 
  Busbars can be found in a wide range of electric vehicles, from small passenger cars to large trucks. Different requirements, dimensions and geometries have to be considered in the manufacturing process of these vehicles. Busbar machines from WAFIOS cover a broad product range. One process step is insulation stripping which can be completed mechanically or with lasers. Mechanical insulation stripping is the right choice for manufacturers seeking rapid cycle times and cost-effective production.  WAFIOS busbar machines can be adapted to the individual requirements of a production process, whether short or long busbars, complex busbars and busbars with or without twisting shall be produced. The BMF series is particularly suited for the production of more compact busbars, such as those installed in vehicles that offer little space. Just like conventional bent parts, the busbars are manufactured in a 3D bending process. The patented WAFIOS tool technology makes very tight radii with a thin profile possible. In addition, the alignment of the busbar ends can be modified in a flexible way by twisting. At the same time, the patented rotary roller infeed unit, which is used in virtually all WAFIOS wire bending machines, offers maximum production speed. During production, only the lighter component is rotated, and not the bending head itself.   Are you looking for a busbar machine that can handle extra-long busbars with a large conductor cross-section? The TWISTER² 25 and TWISTER² 35 are the answer. Originally intended for the tube-bending sector, the TWISTER² has been adapted for e-mobility. The result is a machine that can process busbar cross- sections of 300 mm² and lengths of up to 3,000 mm. The tools use the rotary-draw bending method from the tube-bending sector. They are very gentle on the material and prevent surface deformation, for example. At the same time, there is a sufficient bending moment available to bend busbars of up to 300 mm² over the long as well as the short profile side.  Automation solutions for individual busbars and optimal production processes For the busbar bending machines, WAFIOS offers end-to-end automation solutions for additional or subsequent operations. These include punching various geometries, ultrasonic welding, feeding in and mounting stator connector parts, labelling the busbars and discharging onto workpiece carriers or transport belts in the correct position. This enables manufacturers to increase their productivity, improve quality and reduce the cost per piece.  “With automation solutions like EasyRobot, handling busbars is no problem. The operation of the robot is fully integrated into the bending machine,” says Jörg Eisele of the WAFIOS Executive Board.   Mechanical vs. laser insulation stripping Insulation stripping is an important step when processing busbars. Following insulation stripping, the surface must be free from any residue of the PA 12 material. Mechanical insulation stripping ensures that any trace of the insulating material is removed without leaving any residue behind. For this purpose, a small amount of the core material is also removed. By contrast, physical reasons mean that the CO2 laser always leaves behind a layer in the micrometer range. This layer then needs to be removed with brushes to minimize the volume resistance.  Due to the high level of price pressure in the market, demand for mechanical insulation stripping has continued to rise.  “Mechanical insulation stripping is a cost-effective alternative to the CO2 laser. It helps to reduce the cycle times involved in insulation stripping by 40 percent or more, which means a higher output rate from the entire machine system,” says Eisele.  Fully integrated and highly flexible The insulation stripping system in the BMF 60 and BMF 90 busbar machines offers maximum flexibility, with seven axes and two milling units. The material is first stripped on the top and bottom, then it is rotated by 90 degrees and the side surfaces are machined. The CNC insulation stripping device allows any kind of combination to be produced at the busbar end, depending on the connection situation of the busbar. These include having just one side stripped, the top and bottom stripped or all four sides stripped.  The insulation stripping device is integrated into the machine between the infeed and cutting unit. It is fully adjusted using the simple and intuitive WAFIOS Programming System WPS 3.2 EasyWay.  No matter what requirements are placed on the insulation stripping process, WAFIOS offers the right solution.   

•  New Developments among WAFIOS Wire Bending Machines  (Jul 08, 2025)
  Simple Setup for Rapid Wire Bending Processes
  WAFIOS celebrates diversity – among people and machines. Its wire bending machines offer flexible bending solutions for round or profiled wire as well as for tubes. Modular tool solutions, an assisted setup procedure and a new insulation stripping device are just a few of the many new developments when it comes to wire bending.  Turbulent times bring uncertainty for manufacturers and consumers alike. Yet one thing is certain: WAFIOS machines are a safe investment in the future. The built-to- last machines unite the highest quality standards, innovative developments and increased productivity. The WAFIOS product portfolio extends from wire straightening and cutting machines to chain manufacturing, spring and wire bending machines and is rooted in many years of experience. For manufacturers seeking maximum precision and performance, the High-Performance series are the perfect choice. While for economical production ranging from prototypes to high volumes, the Performance machines are ideal. Defined packages of supplementary equipment round out the optimized basic scope of equipment.  Increase speed with the HighSpeed machines Providing a boost in terms of both speed and performance, the highly dynamic drives of the HighSpeed machines in the BM series raise production to a new level. The powerful machines epitomize flexible production of highly complex bent wire parts, focusing on large volumes and the highest quality standards. Thanks to iQsmartbend, which is already included in the basic price of the BM HS series as a 5-year license, the CNC high-end wire bending machines achieve up to 40 percent higher output, depending on the workpiece produced, compared with the predecessor machines. The iQ function optimizes bent parts fully automatically in terms of their vibrations in the bending process; the reduced vibrations accelerate the bending process and significantly increase the output achieved.  Yet when it comes to manufacturing various bent parts, it is more than simply speed that plays a role.  Straighten with ease Each new wire coil involves a new setup process. The straightening devices are set manually, and the process mainly depends on the experience of the operating personnel. Straightening results and the time required therefore vary from operator to operator. Modern software such as iQplug&straight cancels out these variations. The AI-based iQplug&straight software guides the operator systematically through the optimum setup of the straightening devices.  The iQ function measures a straightened rod with the aid of a highly sensitive measuring assembly outside the machine. The software’s artificial intelligence suggests optimized settings for the straightening rollers, making time-consuming straightening settings a thing of the past.   Modular tool system: always the right bending radius A straightened wire is not the end of the story. Until now, new, adapted bending tools have been needed to deal with new bending geometries or new wire dimensions. Designing and manufacturing these tools costs time and money. The new modular tool system for High-Performance machines solves this problem.  The patented system consists of a toolbox which can be used to put together a bending tool with two bending radii within just a few minutes for the entire operating range of the machine. There is no design or manufacturing stage. Developed specially for the MBS tool, the simplified tool input in the WAFIOS Programming System (WPS 3.2 EasyWay) enables the required process data and characteristics to be created quickly and automatically. The process is based on minimal inputs and can be completed in next to no time. As a result, a new bending tool can be created with ease, or the existing tool configuration can be adapted rapidly.  The bending system is available for wire diameters from 2 to 13 mm and is compatible with the BM and BMU machines. Depending on the wire material and quality requirements, the bending pins are available with or without coating or as a roller.