How to Cut and Fabricate Beryllium Copper Wire for Custom Applications

Beryllium Copper Wire

If you are working on a custom project requiring beryllium copper wire, you may wonder how to properly cut and fabricate it to meet your specific needs. Beryllium copper is a unique alloy that offers excellent conductivity, durability, and resistance to corrosion, making it an ideal choice for various applications. However, due to the composition of this material, it requires special handling and cutting techniques. In this blog post, we will share some tips and tricks to help you cut and fabricate beryllium copper wire for your custom applications.

What is Beryllium Copper Wire?

Beryllium copper wire is a specialty alloy that can be used for various custom applications. It is valued for its superior electrical and thermal conductivity, corrosion resistance, high strength-to-weight ratio, and remarkable fatigue endurance. Beryllium copper wire also has excellent spring properties that make it suitable for many different types of applications like springs, connectors, bus bars, antennae radiation shielding and more. The beryllium content in this type of alloy ranges from 0.4% to 3%, enabling it to resist corrosion in harsh environments and providing cost savings during production runs compared to other alloys. Its hardness makes it ideal for use in electrical components where reliability and performance are key factors. At the same time, the product’s low shrinkage ensures consistent dimensions throughout production runs—critical when precision is essential or multiple parts must fit precisely together without expensive fine-tuning or intricate machining operations. Beryllium copper wire has numerous advantages over its competing counterparts and offers users an ideal solution when creating custom assemblies or components with specific requirements.

How to Cut and Fabricate Beryllium Copper Wire for Custom Applications

Types of Beryllium Copper Wire:

Before you begin cutting and fabricating beryllium copper wire, it is important to understand the available different types. Two main types of beryllium copper wire are tough pitch and high strength. Tough pitch is more ductile and malleable, making it easier to form, shape, and cut. On the other hand, high strength is more rigid and requires more force to cut. Determine the type of wire you will use for your project and adjust your cutting tools accordingly.

Cutting Tools:

When cutting beryllium copper wire, choosing the right cutting tools is important to prevent damage to the wire and ensure a clean cut. Use a sharp, high-speed steel or diamond-tipped saw blade to cut through the wire. Avoid using abrasive cutting discs or grinding stones, as these can cause excessive heat and friction, making it more difficult to cut accurately. Remember to wear protective gear, such as gloves and eye protection, when handling beryllium copper wire.

Fabrication Techniques:

You can begin the fabrication process once you have cut the beryllium copper wire to your desired length. Beryllium copper is relatively easy to form, shape, and bend, making it a versatile material for custom applications. Use a bending tool or jig to bend the wire into the desired shape, and use a mallet or bending tool to fine-tune any curves or angles. You can also use a vice or clamp to hold the wire while working on it.

Finishing Techniques:

After you have cut and fabricated the beryllium copper wire, add a finishing touch to it. Beryllium copper can be polished, plated, or coated to enhance its appearance and protect it from corrosion. Be sure to use compatible plating or coating materials that are designed for use with beryllium copper. If you plan to polish the wire, use a soft cloth or polishing wheel to buff out any imperfections.

Safety Precautions:

When working with beryllium copper wire, it is important to take safety precautions to protect yourself from potential health hazards. Beryllium copper contains small amounts of beryllium, which can be harmful if ingested or inhaled. Be sure to work in a well-ventilated area and wear a respirator or dust mask to prevent inhaling airborne beryllium particles. Wash your hands thoroughly with soap and water after handling beryllium copper wire.


Beryllium copper wire is a valuable material for custom applications due to its excellent conductivity, durability, and resistance to corrosion. However, it requires special handling and cutting techniques to ensure a clean cut and prevent damage to the wire. Following the tips and tricks outlined in this blog post, you can cut and fabricate beryllium copper wire to meet your needs and create a durable and functional finished product. Remember to take safety precautions when working with beryllium copper to protect yourself from potential health hazards.

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