Advanced profile wire rolling technology for high-precision copper and aluminum processing

DEM Group, headquartered in Pavia di Udine, Italy, is a leading provider of advanced rolling mills and drawing lines, offering integrated facilities that include high-speed coiling solutions. The company’s profile wire rolling technology is designed to deliver superior speed, precision, and efficiency, making it a standout choice for manufacturers seeking high-performance solutions for copper and aluminum wire processing.

Unlike traditional drawing or extrusion methods, DEM’s rolling mills are equipped with flattening and edging capabilities. These mills can be configured in 5 or 7 stand setups, providing enhanced control over wire dimensions and surface quality. DEM also offers facilities for removing dust from wire surfaces and high-speed coiling equipment to complement its rolling lines.

Advantages of DEM’s rolling technology

DEM’s profile wire rolling technology offers several key benefits:
• higher rolling speed: operating at speeds of up to 1400 m/min, DEM’s rolling process is significantly faster than traditional wire drawing or extrusion techniques, improving production efficiency;
• longer roll life: the use of advanced rolling technology results in longer-lasting rolls, reducing wear and tear, minimizing maintenance requirements, and eliminating the need for extraordinary interventions;
• superior coiling precision: the system ensures perfect coiling of flat wire, even for extremely small profiles as fine as 0.5 x 1.0 mm, making it ideal for applications that require high precision;
• exceptional dimensional accuracy: DEM’s rolling process achieves outstanding tolerances, with thickness variations as low as 0.002 mm. The result is a perfectly controlled width and corner shape, ensuring a smooth transition from round to plane surfaces;
• optimized surface quality: the process guarantees defect-free surfaces, crucial for applications like wire enameling, where flawless insulation is essential for electrical performance. This is particularly beneficial for industries requiring high electrical efficiency and durability.
• new stand-alone rolling module: DEM has developed a compact and versatile rolling module that can be easily integrated into both new and existing enameling lines. This innovation allows for seamless process integration and production scalability without the need for extensive modifications.

Supporting e-mobility with high-efficiency flat wire

One of the most significant applications of DEM’s technology is the production of flat wire for hairpins in e-mobility power engines. As the demand for electric vehicles (EVs) continues to grow, hairpin winding technology has become increasingly critical for enhancing the efficiency and performance of electric motors.

By providing high-speed, precise, and reliable flat wire production, DEM’s rolling technology plays a vital role in supporting the next generation of electric powertrains. The company’s commitment to innovation ensures that manufacturers can meet the evolving demands of the automotive industry while maintaining cost-effectiveness and quality.

For more information on DEM’s rolling technology and its applications, we invite you to visit the corporate staff at Interwire 2025 tradeshow, taking place in Atlanta (GA) from May 13 to 15, don’t miss it.