The DIWire Bender is the first desktop CNC wire bender. A new archetype for rapid prototyping and small scale production, the DIWire transforms drawn curves into bent wire that can be assembled to make just about anything. The DIWire bends various metals and plastics, allowing for output to be used as the final product. Build volume is limited only by the length of the wire.

The DIWire’s simple input and fast, accurate output enables anyone to quickly explore shapes and structures. Interest in the DIWire ranges from automotive, architecture, furniture, lighting, jewelry, orthodontics, surgical implants, robotics, STEM/STEAM, and more.

The DIWire started out as an internal DIY project. We needed a tool to make the frame and legs of chair prototypes. Hand-bending was our only option, and it was a time consuming and imprecise one. We set out to create a solution, and invented the DIWire. We needed a device that could bend fine wire, rod and tube in materials from steel to plastic. We focused on creating output that is fast, accurate, scalable and repeatable. Above all, we wanted to build a machine that anybody could use and adapt to fit their own needs.

The hardware design challenge revolved around making a strong machine that could handle bending steel rod at a price point that is achievable for small shops. The software challenge revolved around allowing users to CNC bend wire with no programming or CAD skills required - a simple process of loading a file and pressing bend.

We also focused on the entire user experience. The machine and software needed to be simple and intuitive. We wanted to provide seamless workflow, from drawing to printing to assembly. We envisioned the DIWire as a versatile tool that had a broad application. In order for that to happen, it had to be easy enough to use so that users would focus on what they were building and creating rather than trying to figure out the machine. Finally, we strove to achieve an aesthetic that anyone would be proud to show off in their shop.

The DIWire was born out of our own needs as a product design group - a need for better furniture prototypes. The first DIWire Bender was designed and published as an open source DIY project. It straightened aluminum wire from a spool, and then bent it in three dimensions. The response to the open source DIWire was fantastic. So many people were interested, and many even tried to build their own, but only one person succeeded. Most people wanted us to make a DIWire for them. We realized that there was a broad audience who wanted the functionalities of the machine without having to build it. It was then that we began to focus on a wire bender for mass production.

Design research is about getting close to your users and consumers in order to get a deep understanding of their needs and desires. The first machine was open sourced, partly because most of the hardware and technology we used were open sourced so we wanted to give back to the open source community. The larger reason was that we wanted to learn about what people wanted in terms of uses, features, material types and sizes, and projects they wanted to make before we even had a product. By connecting to our target audience first, we could deliver exactly what they needed and desired. We could design the machine for them, and with them.

This collaboration between designer and user drove the machine design and engineering. Many people asked us if they could use the machine for their own projects or businesses, giving us insight into the audience and potential uses for the machine, such as medical, educational, manufacturing, and more. Based on this information, we were able to make the machine strong enough to fit their needs while still keeping it in a reasonable price range. The community also requested features and capabilities that informed our design, such as the ability to quickly swap materials and diameters. Most importantly, we realized that what the community wanted was a simple, versatile tool. We focused on creating a seamless user experience by simplifying the software and making the machine intuitive to use. We also created an ecosystem of products to include with the machine, such as clip assembly helpers and curated material list.

By going to the community first, we already knew that there was a broad audience for the DIWire who wanted to make all kinds of different projects. We created PensaLabs, a community sharing site that would be a central hub for everything DIWire related; a place for all the different individuals, businesses, and industries to come together. People can sign up for mailing lists, give us feedback, learn about the potential and possibilities, and even pre-order the machine. Through PensaLabs, we are able to capture crucial information about our audience, from background to industry to what they wanted to bend. We can also easily connect with our users about updates, problems, and feedback.

The DIWire transforms businesses. As a desktop manufacturing tool, the DIWire enables small and new businesses to compete in the new economy by making local, just-in-time, and short-run manufacturing more viable. As a result, business can serve niches or provide mass customization, opening up new markets and broader satisfaction from consumers. Rather than purchasing mass-produced products, they can purchase the product that satisfies their particular needs. We have already seen the impact that other desktop manufacturing tools have made, such as 3D printers or laser cutters. The DIWire is unique in the desktop fabrication world because we are the only ones who create in wire/tube form.

The DIWire also enhances STEM/STEAM education by simplifying building skills. Learning by building is a very effective way to understand and conceptualize an idea - it helps the concepts stick, whether it’s engineering, math and science principles, or arts and crafts. However, a common barrier to building is that craftsmanship can be intimidating, and students end up spending most of their time learning how to build rather than the concept themselves. The DIWire is a simple tool that can quickly transform a drawn line on the computer to a physical part in minutes, allowing students to easily build and create shapes and structures. It also encourages work with other mediums; one can use the wire as structure and add wood, fabric, paper mache, etc. to finish the project. By simplifying building, the DIWire helps students easily build and learn in the classroom.