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I measured about 5 deg rotation per inch of travel. It rotates the same direction regardless of the direction of advance. And the rotation is not smooth - it's a little erratic. The more I think about it, there is so little contact between the stepper bushing on the wire - just two points on a...

Stick - it's a little erratic I think partly because it's not easy to get a good grip on smooth music wire. I tried a rubber roller but that did not work well. I also tried a sort of knurled roller. JRB - Yes it's a 2D bender. I thought about a right angle bend but don't like the...

I was also thinking that I might need to improve the precision of the prototype. And I like the brake idea though it adds some complexity. Thanks. Will continue plugging away.

Excellent point but I can't ask my customers to do that extra step and the wire does not always rotate in the same direction so it seems something else is going on.

I'm designing a desktop CNC wire forming machine and running into a problem. As the wire advances it is rotating several degrees and not even in a predictable direction. The wire is pushed thru by a V groove in a bushing mounted on a stepper and a free turning bearing with a V groove that is...