Wire Sub-Assemblies
We build precision wire sub-assemblies using coiling, forming, and laser welding for high-performance, tightly integrated applications.
Precision Wire Sub-Assemblies in Nitinol and Specialty Alloys
Motion Dynamics builds precision wire sub-assemblies centered on our core strengths in coiling and wire forming, with laser welding as the primary method of joining. Pull wires represent a significant portion of this work and serve as a clear example of the complexity, precision, and reliability our assemblies are built to support.
These high-performance components are engineered for applications requiring tight tolerances, mechanical strength, and seamless integration with downstream systems. We combine multiple operations—including forming, machining, welding, swaging, and final assembly—within dedicated manufacturing cells designed for process efficiency and repeatability. Laser welding is supported by custom tooling and robust in-process controls to ensure consistency at scale.
Our teams work closely with customers through early design, prototyping, and production ramp-up to ensure every sub-assembly meets performance and manufacturability targets. The result is a fully integrated component that reduces handling, improves alignment, and delivers dependable mechanical performance.
Specifications
- Core Processes: Coiling, wire forming, laser welding, swaging, machining, final assembly
- Typical Materials: 304/316 stainless steel, Nitinol, MP35N, platinum, and other precious metal alloys
- Wire Diameters: 0.003" – 0.070"
- Tolerances: Down to ±0.0005" (depending on geometry and process)
- Assembly Methods: Laser welding (primary), mechanical joining, swaging, custom fixtures
- Manufacturing Approach: Dedicated manufacturing cells for integrated, multi-step production
- Volume Range: Prototype to high-volume production
- Inspection: In-process visual, mechanical, and dimensional inspection per customer requirements
- Design Support: DFM feedback, prototype iteration, and rapid transition to production
Frequently Asked Questions
We focus on precision wire-based sub-assemblies, including pull wires and multi-component assemblies requiring tight alignment and mechanical integrity.
Laser welding is the primary method, supported by mechanical joining, swaging, and custom fixturing.
Yes. We combine forming, machining, welding, and assembly within dedicated manufacturing cells.
We ensure consistency in assemblies through custom tooling, in-process inspection, and cell-based manufacturing designed for repeatability.
Related Applications
Micro Wire Components
Nitinol Components
Guidewires
Pull Wires
Related Industries
We serve a range of advanced industries where precision, performance, and reliability are non-negotiable—from medical and aerospace to automotive, electronics, and beyond.
Cardiovascular
Neurovascular
Orthopedics
Endoscopy
Aerospace
PARTNER WITH US
Let’s build what others can’t.
Whether you’re developing a breakthrough device or scaling a complex assembly, Motion Dynamics has the expertise to help you get it done right. Explore how our engineering team can support your next precision build.