At Less Wire Forms, we take pride in producing high-quality wire mesh cable trays that meet the toughest industrial and commercial demands. But what goes into making these essential cable management solutions?
In this exclusive behind-the-scenes look, we’ll walk you through our manufacturing process, quality control measures, and the technology that sets our wire mesh cable trays apart.
1. Raw Material Selection: The Foundation of Durability
The journey begins with selecting the best raw materials to ensure strength, corrosion resistance, and longevity.
✔ Stainless Steel (304/316) – For harsh environments (chemical plants, marine applications)
✔ Galvanized Steel – Cost-effective yet durable for industrial and commercial use
✔ Aluminum – Lightweight and ideal for data centers and telecom
Every batch undergoes material testing to verify tensile strength and corrosion resistance before production begins.
2. Precision Wire Drawing & Mesh Formation
Our state-of-the-art machinery ensures consistent wire thickness and strength:
- Wire Drawing: Raw metal rods are drawn into precise diameters.
- Welded Mesh Formation: Automated welding machines create uniform grid patterns with high structural integrity.
- Custom Mesh Sizes: We adjust spacing and wire thickness based on load requirements.
3. Robotic Welding for Flawless Joints
We use automated robotic welding to ensure:
✔ Strong, consistent welds without weak spots
✔ Smooth edges to prevent cable damage
✔ Uniformity across every tray section
4. Forming & Shaping the Cable Trays
Our hydraulic presses and CNC bending machines shape the mesh into:
- Ladder-type trays (for maximum ventilation)
- Solid-bottom trays (for added protection)
- Custom widths & depths (2” to 24” and beyond)
Each tray is checked for dimensional accuracy before proceeding.
5. Surface Treatment for Enhanced Protection
To maximize durability, we apply:
- Hot-Dip Galvanizing – For superior rust resistance (ideal for outdoor use)
- Powder Coating – Adds an extra protective layer and aesthetic finish
- PVC Coating – For chemical resistance in food & pharma industries
6. Rigorous Quality Control Testing
Before leaving our facility, every wire mesh cable tray undergoes:
✔ Load Testing – Ensures it meets or exceeds industry standards (NEMA, IEC)
✔ Salt Spray Testing – Checks corrosion resistance in harsh conditions
✔ Visual & Dimensional Inspection – Guarantees defect-free products
7. Packaging & Custom Logistics Solutions
We carefully package trays to prevent transit damage and offer:
- Bulk palletized shipments for large orders
- Custom crating for international exports
- Just-in-time delivery for project timelines
Why Choose Less Wire Forms?
✅ Made in india with premium materials
✅ Custom designs for specialized applications
✅ Strict adherence to international standards (UL, NEMA, IEC)
✅ Fast turnaround times without compromising quality
Conclusion
At Less Wire Forms, we don’t just manufacture wire mesh cable trays—we engineer reliable, long-lasting solutions tailored to your needs. From raw material selection to final inspection, every step is optimized for performance.
Need a trusted supplier for your next project? Contact us today for a quote or custom design consultation!