Headquartered in Easton, Pennsylvania, Sussex Wire specializes in the design, manufacturing and distribution of highly-engineered, specialty metal parts and components. The Company, founded in 1973, utilizes cold-forming technology to form metal wire and specialty alloys at room temperatures into highly engineered precision, micro-miniature components faster in a more cost-effective manner than traditional machining, stamping, metal injection molding and casting methodologies. Sussex Wire has designed and engineered processes that improve product quality and differentiates the Company’s competitive position. The Company serves a variety of global blue chip customers who operate in the medical, electronics, connectors, computer, automobile, transportation, appliance, semiconductors, and glass to metal seal industries.

In 2017 Sussex Wire acquired Marox Corporation, a precision Swiss Machining specialist, to complement the company's capabilities.

Marox Corporation is a leading provider in CNC precision machined orthopedic implants and aerospace components. The acquisition supports the strategy of both companies to address customers’ need for more diverse manufacturing capabilities when developing tight tolerance components for their most demanding applications. MAROX and Sussex Wire’s engineering, manufacturing and quality systems are fully complementary. MAROX’s CNC Swiss Turning, CNC Milling and CNC Mill/Turn machining are a natural extension of Sussex Wire’s cold formed, roll formed and 4-slide capabilities.

MAROX and Sussex Wire will continue to operate as separate entities in Holyoke, MA, Easton, PA and Warminster, PA., with company leadership and employee support remaining the same.

Sussex Wire is one of a very few companies in the world that can produce miniature, precision, geometrically complex, cold headed parts ranging from 10 million to over 1 billion per year. The Company has the ability to manufacture and form symmetrical and asymmetrical components from wire diameters of 0.0035’’ to 0.250’’. While Sussex Wire is capable of manufacturing components using larger than 0.250” diameter wire, it typically focuses on micro-miniature components. The Company is ISO 9001:2015 certified and ITAR (International Traffic in Arms Regulations) compliant. In addition, the Company routinely passes rigorous quality audits from FDA certified customers.

Sussex Wire owns and operates a wide variety of machines specially designed for the cold-forming and cold-heading process, including computerized cold-forming machines, four-slide machines, rolling, forming, tapping, and sink and wire electrical discharge machines. In addition, the Company has custom-built certain machinery to combine certain cold-heading and wire-forming processes to meet customer specifications. Another competitive advantage is Sussex Wire’s ability to work with a variety of different metals, including exotic metals, expansion alloys, nickel alloys, kovar, cobalt, precious metals (gold, silver, platinum, and palladium), copper, steel, brass and stainless steel. Sussex Wire has a complete tool room with state of the art equipment (CNC sinker EDM, CNC wire EDM), plus conventional metal working machine tools oriented towards small diameter work. The Company also has CAD and CAD-simulation capabilities which increases successful set-ups and decreases lead times because troubleshooting can be assessed prior to production.

Sussex Wire Advantages

Quality Driven Processes
Sussex Wire, Inc. is ISO 9001:2008 Certified, and routinely completes Gage R&R capability studies to a Six Sigma Cpk for the most stringent of automotive, healthcare and electronics applications.

Engineering Design To Reduce Total Cost of Ownership
Sussex delivers know-how and technology for its clients evolved from 40+ years of collaborative design experience. CAD/CAM systems integrated with world-class design labs and tooling capabilities provide fast, accurate, consistent turnkey designs. Our twelve design and tooling engineers, formally trained in 3D simulation using advanced software such as SolidWorks, AutoCAD, Inventor and DEFORM, collaborate to achieve the easiest, most cost-effective solutions.

Integrated Manufacturing
State-of-the-art cold forming, cold heading, roll forming, EDM, OMNI, tapping and finishing technologies provide timely and controlled production throughout all primary and secondary operations. Formalized internal and external training and certification for all operations personnel ensures readiness and consistency from one work center to the next.

Rapid Prototyping Saves Time
Our company's “Quick-turn” prototyping capabilities give us the opportunity to make ROI value judgments with our clients before committing extensive resources to new product development (NPD). We value our clients’ precious time and demonstrate it through rigorous milestone and gate review protocol practices that enable us to make “go / no-go” decisions earlier in the NPD cycle.

Lean Six Sigma Continuous Improvement Culture
Our company, staffed by certified Lean Continuous Improvement (CI) Practitioners, embraces Kaizen events in order to deliver greater throughput. This results in better value without sacrificing quality, and ensures on-time deliveries every time. Sussex Wire’s Continuous Improvement Culture starts every part design by identifying the optimal material for the job, and determining the most cost-effective method to produce it and deliver it to the customer. Kaizen events are held as frequently as quantifiable material gaps are identified. We pride ourselves on the fact that we never stop improving.

High Volume Mini and Micro Precision Designs
Sussex Wire is scaled to engineer, produce and control parts to geometries measured in fractions of 0.001” at annual volumes well in excess of one billion per year. This makes the company a recognized global leader in mini and micro part design and manufacture. Healthcare, semiconductor, automotive, energy and electronics clients routinely consult with our design team to transform micro components traditionally produced by screw, Swiss-screw and machine houses into less expensive, high volume cold formed solutions. The tighter the geometry, the more complex the design, and the more difficult the material = the more valuable our services.