Understanding the benefits
Shape setting allows you to take full advantage of Nitinol's unique properties. The first of these is the ability to deform a shape-set part below transformation temperature, allowing it to fit into a smaller space, and return to the original form by exposing it to the transformation temperature. You can also deform a shape-set part above the transformation temperature and it will return to its original shape immediately upon release.
To shape set a part, Nitinol wire is wrapped around a mandrel and heat treated at a closely controlled time and temperature in its desired shape. After the material is quenched and removed from the mandrel, it will remember its shape even after deformation. At Fort Wayne Metals, we use precision fluidized beds as well as other proprietary shape setting methods to meet the requirements of your complex designs. Our engineering team uses in-house design and tooling to offer rapid-prototyping services so you can innovate faster.
Typical end uses
Customizing the specifications of your shape set-part means the possibilities are practically limitless. We've seen our customers utilize shape-set Nitinol for:
- Collapsible stents
- Iris expanders
- Retrieval baskets
- Shaped needles
- Surgical clips
- Suture retrievers
Design specifications
The details of your custom shape-set parts are up to you. Depending on the grade of Nitinol utilized, transformation temperatures for shape-set parts can range from -15 °C to +100 °C [5 °F to +212 °F]. We can shape set the following product forms in sizes ranging from 0.0254 mm to 2.000 mm [0.001 in to 0.0787 in].
- Flat wire with a rectangular cross section
- HHS® tube with an open working channel
- Round wire with a circular cross section
- Shaped wire with specialty shaped cross sections
- Strands & cables in complex constructions for advanced applications
You can further customize your shape set-parts with one of the following surface finishes:
- Electropolished for the smoothest surface and best corrosion resistance
- Etched by chemical removal of oxide layer for a matte silver appearance
- Oxide dark purple or blue in appearance
- Surface conditioned for an oxide-free appearance similar to stainless steel
Assembly and testing capabilities
Need to do more with your shape-set parts? We can help with additional processing such as:
- Coining/flattening for end stops or location specific widening
- Custom assembly for custom crimps and fittings
- EDM cutting for tight tolerances, burr-free cuts, and square-end cuts
- Weld beads in full radius or large beads greater than wire diameter
You can also count on us for additional inspection steps, such as:
- Corrosion testing per ASTM F2129 and F3044
- Dimensional analysis of full validation runs (PPAP) and First Article Inspection (FAI)
- Finish Af testing using Differential Scanning Calorimetry (DSC), Bend and Free Recovery (BFR), and ASTM F2082
- Mechanical testing per ASTM F2516
- Surface roughness testing by non-contact surface profilometer