Primary process: Soldering. The full route, materials, tolerances and design tips for a wire join, with an indicative cost.
SolderingPrimary process
JoiningFamily
5Route steps
A wire join is primarily made by Soldering. Soldering joins metal with a filler melting below 450 C, used for electrical and plumbing connections and fine assembly. Below is the full route to make a wire join, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a wire join is made
The usual route, raw material to finished part. The amber step is where the wire join gets its basic shape.
Prepare the parts
Make and clean the components the wire join brings together.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Fit-up
Jig and align the parts, set the gap and tack where needed.
Soldering
Join the parts at low temperature to form the wire join.
Tooling Low Tolerance good Lead immediate
Clean and finish
Dress the joint, remove flux or spatter, and coat if required.
Inspection
Inspect the joint visually and, for critical work, by NDT or leak test.
Need the real cost for a wire join? The free route above is yours. Unlock the full dossier to quote and source it.
General pointers. The full design-for-manufacturing list for a wire join is in the dossier.
Relying on solder for strength.Add a mechanical retention.
Poor thermal relief.Design pads/reliefs.
Cost
What a wire join should cost
Low-temperature electrical/plumbing joints; cheap and fast, strength is modest. Mechanical, not structural.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a wire join at your volume, in your currency, are in the dossier.
MODEL EST.
$0.49 to 0.83per part at 100 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
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Everything you need to quote and source it
The free route above is yours. To actually put a number on a wire join and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
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A wire join is primarily made by soldering. The route is: Prepare the parts; Fit-up; Soldering; Clean and finish; Inspection.
What does a wire join cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $0.49 to 0.83 per part at 100 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a wire join made from?
Common choices are Lead-free solder (SAC); Copper + solder.
What is the main process for a wire join?
Soldering. Electronics, copper plumbing and delicate joints.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
