By combining advanced induction heating, precise process control, repeatable machine set up and an environmentally friendly water-quenching system, DEM delivers spring wire with exceptional mechanical properties ready for immediate cold coiling and end-use production.

The backbone of modern industry

Spring wire is a critical material across multiple industries, from automotive and industrial manufacturing to aerospace and infrastructure. Its ability to withstand repeated stress while maintaining its original shape makes it essential for high-performance applications such as suspension systems, engine valves, large door springs, and mechanical components. As product demands increase, manufacturers require spring wire with higher strength, improved fatigue resistance, and absolute consistency – without adding complexity or cost to their operations.

Clean, continuous, and cost-effective

At the core of the DEM system there is a continuous process starting from wire rod. The entry material is pre-straightened, cleaned by removing the rust and drawn to achieve the proper inlet tensile. The wire is perfectly cleaned from soap residuals prior to heating in the induction furnace. The system integrates advanced mechanical handling, high-performance induction heating, and a state-of-the-art PLC automation platform. Real-time monitoring of tension, temperature, line speed, and power output ensures repeatable quality from start to finish. The water-based quenching system is free from oils, polymers, or lead. This clean solution:

– eliminates quench oil handling and disposal costs

– reduces fire and pollution risks

– simplifies environmental compliance

– delivers consistent martensitic structures across the entire wire length

The result is a safer workplace, lower operating costs, and a smaller environmental footprint.

Intelligent automation and process control

Another advantage of the DEM system is the intelligent setup of the machines, achieved through automatic configuration of all process equipment. The operator can set up the line by recalling a recipe stored in the PLC.

Automated weld detection and removal, precise tension control, and decentralised communication modules further enhance reliability and ease of operation. Surface defects of the wire can be tracked, painted, and eliminated straight away during the ceaseless process, without interrupting production.

The DEM spring wire Q+T Lines are engineered to ensure high productivity. The system continuously hardens and tempers high-carbon spring steels, such as SAE 9254, achieving tensile strengths up to 2,000MPa.

With line throughput of 3t/h, DEM enables manufacturers to significantly increase output while maintaining absolute process control.

Most importantly, DEM stands behind its technology with performance guarantees covering:

– dimensional stability with in-line section control

– surface quality

– defect control with an inline Non Destructive Test apparatus

– tensile strength and uniformity

Wire Up: The digital platform for modern wire manufacturing

DEM's commitment to digitalisation is embodied in Wire Up, an IIoT platform specifically developed for the wire industry. This comprehensive digital solution addresses the full spectrum of operational needs, from real-time monitoring to predictive maintenance.

Wire Up delivers:

– Monitoring capabilities that provide access to machine data from anywhere, ensuring stakeholders stay informed in real time.

– Automatic alerts for malfunctions, non-conformities, or missed targets, enabling rapid response.

– Troubleshooting support leveraging operator-built knowledge for prompt, effective action.

– Predictive maintenance based on memorised practices and advanced analytics.

– Data analysis tools that make big data exploration accessible, identifying improvement opportunities.

– Process modelling to maintain control over each task in the production workflow.

– Spare parts management through browsable 3D drawings for efficient inventory control.

The platform enables manufacturers to reduce time to market, increase repeatability, and enhance plant efficiency and safety. With over 100 wire manufacturers worldwide already utilising “Wire Up”, the platform has proven its value in diverse operating environments.

A smarter investment in spring wire production

A DEM spring wire induction tempering line is more than a production system – it is a strategic investment. By increasing throughput, improving quality, reducing environmental impact, and enabling advanced cold coiling, DEM helps manufacturers lower total cost of ownership while delivering superior products to market faster.

wire 2026, hall 11 booth F 42

DEM S.p.A.

Viale del Lavoro, 23

Z.I.U. - Lauzacco

33050 Pavia di Udine (UD) /Italy

Contact person is Enzo Stucchi

Tel.: +39 0432 867601

sales@demgroup.com

www.demgroup.com