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Cross Wire

Cross Wire

Crosswire Welding Challenges Made Simple with Sunstone

When your crosswire welding process requires a specific standard for strength and reliability, a Sunstone micro welder provides the accuracy and flexibility you need. Digital energy controls result in more dependable welds. And with the ability to use different weld heads and electrode styles, Sunstone offers the flexibility to meet any crosswire welding challenge.

Precision Energy Control and Reliability

Even one faulty crosswire weld can weaken an entire mesh panel and cast a shadow on your reputation. With a Sunstone micro welder, you’re able to dial the energy discharge to one-hundredth of a watt second and make adjustments to adapt to different material types and dimensions. For crosswire welding, heating elements, mesh reinforcements, micro-scale joints, and wire grates speak with a Sunstone crosswire welding expert now.

What are you welding today? Call or text us at +1-801-658-0015.


Cross wire welding is a very common welding application used in many everyday products and devices. It is one of the most common non-automotive applications for resistance spot welding.

Some common cross wire welding applications are heating elements, baskets and cages, and fences. In addition, cross wire welding is used to weld reinforcing mesh found in buildings, roads, tunnels, concrete, and prefabricated components.

Other applications include nanoscale cross wire welding for micro-scale joints found in many electronic appliances. Sunstone Engineering designs and manufactures various different welding solutions to meet your specific cross wire welding needs. Contact us for further information concerning your application and needs.

cross wire welding


  • Heating Elements
  • Mesh Reinforcements
  • Micro-Scale Joints
  • Baskets and Cages
  • Wire Grates
  • Fences

For more information about cross wire welding applications, please Contact Us.

Video Information

The WH1125A weld head is configured with an 1/8″ copper upper electrode that has been notched at the tip to accept the 0.044″ wire diameter. The lower electrode is a copper grounding plane. The force setting is increased to 15lbs to help squeeze the steel together and help alleviate weld splash.

The CDDP 600 is set to 90ws total energy for the T316L and T317L annealed samples. Pulse 1 is set to 9ws energy (10%) and is used to clean the weld area of contaminants before the main weld discharge (pulse 2). Pulse 2 is set to 81ws energy for a strong weld nugget. We pulsed a flow of argon from one side during the weld to demonstrate the difference that can be seen when oxygen is removed from the weld site.

The Hard T316L wire samples were welded at a slightly higher setting of 120ws total energy, 12ws pulse 1, and 108ws pulse 2. Even with argon flowing these welds did not look as clean as the annealed stainless steel samples. All the welds have good pull strength and the notch in the upper electrode helps to minimize wire deformation during the weld.

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  • Micro Resistance - Advanced Dual Pulse CD Spot Welder

    The CDDP-A Dual Pulse Advanced Capacitive Discharge Spot Welder comes in a 200, 400, and 600ws power option.

    CDDP-A Welders Datasheet

    CDDP-A Welder User Manual

    • $8,500.00
  • Opposed Weld Head

    The WH1 pneumatic opposed weld heads offer precision and repeatability at an affordable price. The WH1125A Opposed, MAC Valve Air-Actuated Weld Head comes with a foot pedal, trigger cable, and 1 AWG grounding cables.

    WH1 Weld Head Datasheet

    WH1 Weld Head User Manual

    • $3,700.00
    • $15,500.00
  • High Force Opposed Weld Head

    The Sunstone WH1187A-HF High Force Weld Head comes standard with beneficial features such as manual or automatic triggering, easy force adjustment, and adjustable height.

    WH1 High Force Weld Head Datasheet

    • $6,450.00
    • $0.00
    Out of stock