Abstract: An apparatus and method for calibrating an automated wire bending machine is provided that includes a camera system comprising a camera and a lens configured with a focal plane fixedly positioned relative to a bending surface provided on the automated wire bending machine. The disclosed apparatus and method further includes a processor device configured to interpret images captured by the camera system. The apparatus and method measures an actual angle formed in a wire while a bent portion of the wire is substantially within the focal plane of the camera system, and a memory device stores values generated during a calibration sequence of the automated wire bending machine. The values correspond to the actual angle and a target angle provided for the calibrating of the automated wire bending machine.

Abstract: A simplified wire bending machine is provided comprising a bending head with an integrated wire cutoff mechanism. The bending head comprises an inner portion, wherein the inner portion includes a wire bending channel; and an outer portion, wherein the outer portion includes a cutting edge and one or more bending pins. The outer portion is rotatable about the inner portion such that a bending pin is capable of bending a wire around the inner portion. Further, the outer portion is movable from a first position to a second position in which the cutting edge is configured to engage and shear a wire.

Abstract: A system and a method is provided in which a CAD system receives a solid model and receives user input to select points on the surface of the solid model, to create a wire part program file based on the selected points, and to transmit the wire part program file to a bending machine. The wire part program files is configured such that the bending machine will manufacture a wire based on the wire part program file.

Abstract: A system and a method is provided in which a CAD system receives a solid model and receives user input to select points on the surface of the solid model, to create a wire part program file based on the selected points, and to transmit the wire part program file to a bending machine. The wire part program files is configured such that the bending machine will manufacture a wire based on the wire part program file.

Abstract: An apparatus and method for calibrating an automated wire bending machine is provided that includes a camera system comprising a camera and a lens configured with a focal plane fixedly positioned relative to a bending surface provided on the automated wire bending machine. The disclosed apparatus and method further includes a processor device configured to interpret images captured by the camera system. The apparatus and method measures an actual angle formed in a wire while a bent portion of the wire is substantially within the focal plane of the camera system, and a memory device stores values generated during a calibration sequence of the automated wire bending machine. The values correspond to the actual angle and a target angle provided for the calibrating of the automated wire bending machine.

Abstract: A simplified wire bending machine is provided comprising a bending head with an integrated wire cutoff mechanism. The bending head comprises an inner portion, wherein the inner portion includes a wire bending channel; and an outer portion, wherein the outer portion includes a cutting edge and one or more bending pins. The outer portion is rotatable about the inner portion such that a bending pin is capable of bending a wire around the inner portion. Further, the outer portion is movable from a first position to a second position in which the cutting edge is configured to engage and shear a wire.

Abstract: A method of inspecting a part comprising projecting a life sized image of at least one portion of a selected part file onto a flat surface with a projector, placing a part adjacent to the flat surface, comparing the part to the life sized image of the at least one portion of the selected part file, receiving at least one command at a user interface to modify the life sized image such that it matches the part, and adjusting a manufacturing process based on the at least one command using a control system.