Compacting Heads

Wire compacting heads are fitted with tungsten electrodes and are used to simultaneously deliver welding current and apply vertical force to “compact” wires into a defined shape. During the compacting process, ceramic tooling inserts apply sideward force, helping control the final compacted geometry.

This coordinated application of electrical current and mechanical force enables controlled reshaping of wire conductors while maintaining material integrity.

Copper Wire Tube Compact stranded Copper Wire - Resistance Welding - Stainless Steel 304 - Resistance Welding, STA-100A, UB29A, 180A/EZ, Medical Resistance Welding, Copper Stainless Steel, 304 Copper Wire Tubecompact, stranded Copper Wire

How Wire Compacting Heads Operate

Wire compacting heads apply:

  • Vertical force through tungsten electrodes
  • Electrical current through the wire bundle
  • Lateral force through ceramic inserts

Together, these forces compress and form the wire into the desired compacted cross-section while controlling the final dimensions.

Wire Compacting Equipment Selection Considerations

Selecting the appropriate wire compacting equipment depends on:

  • The material type
  • The nominal cross-section of the wire or wire bundle
  • The required final compacted dimensions

Proper equipment selection ensures that the compacting process achieves the intended shape and performance characteristics for the application

Compacting Heads

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