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Wire Stitching Advantages Cheat Sheet (DRAFT) by [deleted]

Wire Stitching Advantages

This is a draft cheat sheet. It is a work in progress and is not finished yet.


Most areas of manufa­cturing have had steady paces of techno­logical innovation over the past 50 years. Material assembly and material joining is one area, however, that has not kept pace. It is one of the few segments of manufa­cturing that has advanced slowly, if at all, relying on just a handful of assembly techniques for decades. Luckily, new material assembly techniques have begun to crop up in recent years, giving the sector a much-n­eeded infusion of innova­tion. Conven­tional wisdom assumes that when assembling materials there are only five fastening methods, but smart manufa­cturers are increa­singly turning to a sixth method called wire stitching. Each method has its own pros and cons.

Conven­tional five fastening methods

1. Mechanical (hardware) Assembly – Using various different types of hardware or fasteners (bolts, nuts, screws, etc.) and predrilled holes in the material to assemble multiple parts together.
2. Welding – Fusing two or more pieces of metal (similar type of metal) together to essent­ially become one.
3. Riveting – Inserting a small metal component and plasti­cally deforming each end to hold the material in place.
4. Adhesive Bonding – Applying glue to material to hold pieces together.
5. Brazing – Using a filler metal that is melted to a certain temper­ature which will bond the two components together.

Wire Stitching Advantages

Generally not as strong as welding or brazing for steel to steel applic­ations.
Limitation of material thickness. Typically materials that are thicker than 3/8 of an inch are not good candidates for stitching, but it depends on the types of material. Thick, dense materials like steel or ceramics work better for stitching if they are thinner sizes.
Clinched end of staple can show up on the back side of materials depending on material type or wire used.
Joints cannot be easily disass­embled.

Wire Stitching Advantages

Easy to stitch metallic materials (similar and dissim­ilar) that are not readily welded.
Efficient joining of metallic to non-me­tallic materials, great for reducing weight of metal assemb­lies.
Requires no time-c­ons­uming prepar­ation, such as pre-pu­nching, drilling, tapping, critical hole alignment for riveting, or cleaning work (before or after) as with welding and adhesives.
Lends itself well to automa­tion. Stitching heads can be mounted to robot arms or other automation fixtures and tools to enable stitching in any location or in multiple locations.
Quickly and accurately vary the length of the wire draw of the stitching head to adjust for different thickness of work.
Configure to “stab stitch” or staple with no back clinch that allows for stitching even when there is no room to get behind the substrate.
Can attach round or odd shaped parts to flat materials tightly.
High shear and tensile strength.
Not sensitive to heat or cold.
Extremely low cost process that can be done at high speed and with minimal operator training.
Can use stainless steel wire when corrosion resistance is required.
High resistance to joint fatigue and vibration. The tight joint, produced by wire making its own hole and effective clinching action (plastic deform­ation of the staple) restricts movement of parts and leads to extremely long joint life.
Requires only visual inspection to determine if the materials are fastened properly.
Does not require material temper­ature be elevated, keeps shape and material stable throughout the manufa­cturing process.
Extremely short cycle time, as low as one cycle per three seconds.
Variable sizes of staples (crown sizes).
A wide range of commer­cially available wire to be used on the stitching machine.
No backing material needed during assembly process.
Stitcher does not negatively affect the surrou­nding material including paint and other aesthetic details.