Turning Complex Production Challenges Into Automated Solutions

The Challenge

Automating Medical Guide Wire Production

At Novo Precision, some of the most successful automation projects begin with a unique manufacturing 
challenge. By combining proven servo feed technology with application-specific equipment, Novo can develop 
systems that improve efficiency, maintain part quality, and reduce the amount of operator involvement 
required.

A manufacturer needed an automated system capable of producing medical guide wires in a variety of lengths 
with minimal operator involvement. The finished wires needed to have minimal burrs after cutting and be 
automatically separated into groups based on length. 
The application presented an additional challenge: guide wires could reach lengths of up to 100 inches, 
requiring the system to maintain straightness while accurately feeding, cutting, and handling each finished 
wire.

The Solution

Novo utilized a #2 Servo Feed System to feed guide wire from spools using a motorized fine wire payoff. 
Because of the extended wire lengths, a rotary straightening system was incorporated into the process. 
A loop control device maintained a reservoir of straightened wire between the rotary straightener and servo 
feed rolls, helping provide consistent material to the feed system. 
For cutting, a standard #3 Cutter Head with a quill-on-quill tooling arrangement provided the high-quality 
shear cut required for the application. 
Novo also designed a custom conveyor-dump tray attachment capable of pulling the guide wires as they were 
fed, accommodating finished lengths of up to 100 inches. Once the programmed feed cycle was complete, the 
cutter actuated and the finished guide wire was ejected into a collection tray. 
The servo feed software brought the process together by controlling the feed, cut, convey, batch, and eject 
functions. Multiple guide wire lengths could even be programmed during the same feed cycle, automatically 
segregated on the conveyor, and deposited into independent batches.

The Result

The completed system transformed a complex guide wire production process into an integrated automated 
operation. Instead of requiring extensive operator involvement throughout production, the system could 
manage multiple stages—from feeding and straightening through cutting, conveying, batching, and collection. 
Most importantly, the solution addressed the manufacturer's core requirements: producing multiple guide 
wire lengths, maintaining a high-quality cut with minimal burrs, handling lengths up to 100 inches, and 
keeping finished products separated into same-length groups.