FL-602
Axial lead cutting & forming
Axial lead cutting and forming with adjustable lead length and spacing. Available in U, F, and S configurations; confirm packaging compatibility before ordering.
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RESISTOR LEAD CUTTING & FORMING
Resistor Forming
Machines
Accurate lead dimensions. Consistent forming. Reliable PCB insertion.
Cut and form axial resistor leads to your required lead length, pitch and bend shape. Choose from solutions for taped or loose components, with tooling matched to your resistor specifications and production requirements.
What is a resistor
forming machine?
A resistor lead forming machine cuts and bends axial resistor leads to the specified spacing, length, and shape before through-hole PCB assembly.
Also known as a resistor lead former or lead cutting and bending machine, it prepares resistors for horizontal or vertical mounting. Tooling is selected according to the PCB hole spacing, mounting height, and component specifications.
Why use resistor lead forming machines?
Achieve consistent resistor lead dimensions, reduce manual processing and prepare components for reliable PCB insertion—from small batches to continuous production.
Reliable PCB fit
Precision tooling controls lead length, pitch and bend geometry, helping formed resistors align consistently with PCB holes and reducing insertion problems.
Faster production with less labor
Cutting and forming are completed in one operation. Optional automatic feeding supports continuous processing and reduces repetitive manual work.
Reduced component damage
Controlled bending positions and proper lead support help reduce stress near the resistor body, minimizing cracked coatings, loose end caps and deformed leads.
Flexible setup for different resistors
Adjustable settings and interchangeable tooling accommodate different resistor sizes, lead diameters, pitches and horizontal or vertical forming requirements.
Common resistor leadforms
Specify lead spacing, cut length, mounting height, bend location, and dimensional tolerances on the drawing.
Horizontal U-form
Vertical form
Single stress-relief bend
Double stress-relief bends
Horizontal standoff
Vertical standoff
Lock-in form
Underbody form
Offset form
Custom lead forming requirements
Send a component sample and drawing for short leads, special bends, or combined forming and welding operations.
Our resistor lead forming machines
Compare models by feeding method and forming operation. Contact us to confirm tooling, component compatibility, and production capacity.
FL-612
Horizontal & vertical forming
Forms carbon film and metal film resistor leads. Interchangeable tooling supports horizontal and vertical mounting. Optional lead clamping is available.
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FL-606
Automatic axial lead forming
Automatic axial lead cutting and forming with a vibratory bowl feeder. Confirm the feeding configuration for bulk or tube-packed components.
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FL-611
Bulk horizontal forming
Cut and form bulk axial resistors in a single operation for horizontal mounting.
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FL-608
Horizontal resistor forming
Horizontal forming with dedicated bulk- or tube-feeding configurations and application-specific tooling.
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FL-609
Vertical resistor forming
FK-series resistor lead forming equipment. Contact us to confirm the forming direction, feeding configuration, and tooling for your drawing.
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FL-610
Tube-packed vertical forming
Vertical lead cutting and forming for tube-packed axial components. Confirm tube dimensions and available lead length.
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FL-621
Resistor forming & welding
Integrates automatic feeding, cutting, bending, welding, and unloading for resistor assembly.
View DetailsAvailable lead forms, feeding methods, and production capacity vary by model and configuration. Submit your drawing and output requirements for machine selection.
Why use resistor lead forming machines?
Achieve consistent resistor lead dimensions, reduce manual processing and prepare components for reliable PCB insertion—from small batches to continuous production.
EV Charging & Power Electronics
Solar Inverters & Renewable Energy
Industrial Automation & Motor Drives
Data Center & UPS Power
Telecom & Network Power Systems
Power Supply Manufacturing
Resistor Lead Forming Troubleshooting Guide
| Issue | Possible Cause | Recommended Action |
|---|---|---|
| Incorrect lead spacing | Incorrect forming-pitch setting, worn tooling, component misalignment or lead springback. | Set the forming pitch according to the approved drawing. Inspect the tooling and component alignment, then measure the formed sample and verify its fit with the PCB. |
| Inconsistent cut length or mounting height | Incorrect positioning reference, unstable feeding, an improperly adjusted feed stop or worn cutting blades. | Confirm the measurement reference and adjust the feed stop. Inspect the cutting blades and compare the first formed parts with the approved sample. |
| Lead deformation or body coating damage | Rough tooling surfaces, burrs, excessive forming force, insufficient lead support or bending too close to the resistor body. | Inspect the tooling surface and clearance. Adjust the lead support and forming force, and maintain the required bend radius and distance from the resistor body. |
| Feeding jams or component misalignment | Incorrect feeder setup, mixed component sizes, damaged parts, tangled leads or improper feeding orientation. | Separate components by part number and remove damaged parts. Adjust the feeder guides, component orientation and feeding speed. |
| Incorrect dimensions after changeover | Incorrect tooling, retained settings from the previous part number or incomplete machine adjustment. | Install the correct tooling and load the approved settings for the new part number. Perform a first-article inspection before restarting batch production. |
Resistor forming knowledge center
Practical guides for understanding the forming process, defining lead dimensions, selecting equipment, and solving common production problems.
Equipment for Resistor Lead Cutting andForming
Compare forming equipment for taped, loose, horizontal, and vertical
resistor applications.
Axial Resistor Lead Forming Workflow
Follow the process from lead cutting and bending to final PCB-readygeometry.
Standards Resistor Lead Forming Dimensions and Standards
Review lead length, pitch, bend position, and PCB layout considerations.
Resistor Forming Machine Troubleshooting
Identify common forming defects, likely causes, and corrective actions.
Custom equipment
process
We evaluate your component and production requirements to determine the required tooling, feeding system, and machine configuration.
Submit requirements
Provide component samples, a forming drawing, packaging details, and the required production output.
Confirm the equipment proposal
Review the proposed lead form, feeding system, tooling, and additional
operations with our engineers
operations with our engineers
Approve formed samples
Check dimensions, surface condition, and PCB fit against the agreed acceptance criteria
Confirm the order
Confirm the quotation, equipment specifications, utility requirements, delivery
schedule, and installation support.
schedule, and installation support.
FAQ
Answers to common questions about component compatibility,
tooling, pricing, and sample testing.
tooling, pricing, and sample testing.
What resistor sizes and lead dimensions can the machine handle?
Our resistor lead forming machines support a wide range of common axial resistor body sizes and lead specifications. To confirm compatibility, send us the resistor body dimensions, lead diameter, lead pitch, target lead length, packaging type, and required forming style. We can recommend the appropriate configuration and arrange a sample test if needed.
How consistent are the formed leads, and can the process reduce insertion and soldering issues?
The machine is designed for repeatable cutting and bending so lead pitch, lead length, and bend angle remain consistent across batches. This helps reduce hard insertion, misalignment, uneven lead protrusion, soldering variation, and rework associated with manual forming.
What forming styles can the machine produce?
Depending on the machine and tooling configuration, available processes may include lead cutting, horizontal U-forming, vertical forming, standoff bends, stress-relief bends, and other application-specific shapes. Send us the target lead form, final pitch, and component drawing so we can confirm the appropriate tooling and machine configuration.
What maintenance is required, and which parts typically wear?
Routine maintenance includes cleaning, lubrication, and periodic inspection. Typical wear parts include cutting blades and forming tooling, depending on the lead material and production volume. We provide recommended maintenance and spare-parts guidance to help plan service and reduce unexpected stoppages.
What is the lead time, and how do shipping and installation work?
Lead time depends on the machine configuration and required customization. We confirm the production schedule after the component samples, forming specifications, and equipment configuration are approved. Remote installation guidance or on-site support can be arranged according to project requirements.
How much does a resistor lead forming machine cost?
The price depends on the model, feeding system, tooling, component range, and additional operations. Submit a component drawing, packaging details, and production requirements for a quotation covering the equipment, options, spare parts, and shipping.
When should I use manual or automatic lead forming?
Manual equipment may be suitable for prototypes and small batches. Automatic equipment may be more suitable for regular production. Compare production volume, changeover time, labor requirements, dimensional tolerances, and total operating cost.
Can I request sample testing before ordering?
Contact us to arrange a forming test using your components and drawing. Evaluate lead dimensions, surface condition, and PCB fit against the agreed acceptance criteria. Confirm production capacity, changeover requirements, utilities, spare parts, and support in the equipment quotation.
Why Choose
FLOURISHE?
From Japanese-steel forming tooling and Mitsubishi PLC controls to custom engineering and sample-based testing, we build resistor forming solutions for reliable, repeatable production.
Precision Tooling Made from Japanese Steel
Our cutting and forming tooling is manufactured from imported Japanese tool steel for improved wear resistance, dimensional stability and consistent forming during repeated production.
Reliable Mitsubishi PLC Control
Mitsubishi PLC control provides stable machine operation, accurate process control and convenient parameter adjustment for consistent batch production.
Experienced Forming Engineering Team
Our engineering team evaluates the resistor body, lead material, lead diameter, target pitch, cut length and bend shape before developing the forming solution.
Custom Tooling for Your Components
Forming tooling can be customized according to your resistor samples, component drawings, PCB hole spacing and required lead shape, including horizontal and vertical forming configurations.
Sample Forming Test Before Shipment
Before shipment, the machine is test-run with your component samples. Formed parts are inspected against the confirmed dimensions and forming requirements before final approval.
Production and After-Sales Support
Organized production scheduling and inventory control help coordinate machine components, tooling and commonly used spare parts. After delivery, our team provides operating guidance, troubleshooting and replacement tooling support.
Send your resistor sample for a forming test
Provide a component sample, forming drawing, packaging details, and required hourly output.
