Esteves Group: Precision Dies Engineered for Performance, Efficiency and Longevity

Esteves Group, specializing in dies, extrusion tools, and advanced inspection equipment, has recently launched ‘EZero’ range of high-performance dies and has set new benchmarks in precision manufacturing by producing ultra-fine dies down to 0.007mm for various industrial applications. The company has expanded its capabilities with Esteves Malaysia and has launched a second facility in China. In an exclusive interview with Wire & Cable India, Mr. Alex Casanovas, Director-Sales EMEAI of Esteves Group shares insights about the company’s latest technological advancements and expansion plans, emphasizing how their precision dies and advanced tools have significantly enhanced the efficiency and longevity of wires and cables.

Wire & Cable India: Can you give us a company overview, its history and development over the years?

Alex Casanovas: Founded in 1913, Esteves Group has been a global leader in precision tooling for over 110 years. With a legacy rooted in craftsmanship and forward-thinking engineering, the company has grown into one of the most trusted die manufacturers for the wire and cable industry.

The company has manufacturing and support facilities in Europe, North America, Asia, Spain, Poland, the USA, Mexico, China, and Malaysia. Over the decades, Esteves Group has pioneered significant advancements such as introducing polycrystalline diamond (PCD) dies in the 1970s, and launching synthetic single-crystal diamond (SSCD) dies in the 1990s. Most recently, the company has launched its innovative ‘EZero’ range of high-performance dies, proprietary software and smart inventory systems. With these new developments, Esteves Group continues to be at the forefront of innovation in the wire and cable industry.

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WCI: What are the key milestones and major achievements that have led to the growth and success of your company?

AC: We, at Esteves Group, have pushed the boundaries of precision manufacturing and are now producing ultra-fine dies down to 0.007mm for industries like microelectronics and medical devices.

Further, we have broadened our reach and enhanced our capabilities by establishing Esteves Malaysia and launching a second facility in China, thereby expanding our global footprint and operational capacity.

We have also developed a complete suite of software solutions for drawing die profile design, including the Drawing Die Wizard, Eddie Wire Solutions app, which is now used by over 10,000 users worldwide, providing essential support across platforms.

We have introduced the Eddie Vending System, the industry’s first tooling vending solution tailored to the wire and cable sector, paired with the Eddie Vending Wizard app.

WCI: Could you elaborate on your product portfolio that caters to the wire and cable sector?

AC: We manufacture dies for wire diameters ranging from 0.007mm to 50 mm, serving industries such as automotive, telecommunications, microelectronics, medical technology, and high-performance specialty alloys.

The portfolio includes round and shaped wire drawing dies, stranding and bunching dies, extrusion tooling, die refurbishing and recutting service, advanced inventory management via the Eddie Vending System which is a smart tooling storage and access solution tailored specifically to the wire and cable industry. Every product engineered by the company delivers precision, reliability, and longevity, regardless of the application.

WCI: What sets your dies apart from your competitors?

AC: Esteves Group offers a comprehensive range of wire drawing dies including natural diamond (ND), synthetic single-crystal diamond (SSCD), polycrystalline diamond (PCD), carbide, and two specialized materials: EZero dies and DC dies.

EZero dies are Esteves Group’s proprietary solution for applications, having high consistency and longevity, especially with non-ferrous and specialty wire materials. It offers predictable wear behavior and smooth drawing under demanding conditions.

DC or diamond-coated dies combine the wear resistance of polycrystalline diamond with the large-format capabilities of tungsten carbide. This unique blend enables large dies that offer low friction, smooth wire surface finish, and dramatically reduced manufacturing costs.

Esteves Group uses enhanced diamond processing techniques across all materials, with strict 100% quality inspections, and proprietary polishing to ensure reliable performance, minimal defects, and consistent results, even in high-speed or high-precision environments.

WCI: What are the key process improvements and technological advancements at Esteves Group that have enabled efficiency gains for wire manufacturers?

AC: Esteves Group’s tooling is engineered for maximum process efficiency and minimum material waste. Benefits include lower scrap rates through consistent die geometry and tight tolerances; reduced energy consumption due to smoother finishes and optimized flow; fewer wire breaks and longer die life, reducing production interruptions and faster production speeds with stable wire surface quality. These improvements are strategically aligned with our customers’ objectives to boost output and reduce their total cost of ownership.

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WCI: What are the recent technological innovations and developments happening in your company?

AC: The recent technological innovations in our company include the Eddie Vending Wizard—an app that integrates with the Eddie Vending System to provide customers with complete visibility into die inventory, layout, activity, and restock needs—and the Next-Generation Drawing Die Wizard, which features advanced elongation calculations and offers even more powerful support for wire process planning and die selection.

WCI: What is the vision and roadmap for the future?

AC: Esteves Group continues to invest in material innovation; digital tools for die design and inventory management; smart and localized manufacturing; and customer-centered service and sustainability.

As part of Sumitomo Electric Industries, Esteves Group is poised to scale its capabilities globally, bringing smarter, faster, and more reliable die solutions to customers around the world.