hpulcas GmbH has developed a process for the production of compound wires from metal strips. The method enables a wide range of material combinations to be produced in wire form without conventional alloying procedure. These wires can be used as feedstock for thermal coating processes and additive manufacturing processes as well. The basic concept of the technology is the folding of the layered metal strips in a specific stepwise sequence using a multi-stand profiling machine. While the outer material forms the sheath of the composite wire, the inner metal strip replaces the material usually introduced in powder form in conventional cored wires. A wide range of alloys can be produced by suitable fabrication of the stock materials and profiling geometry, and these can also be further processed by forming and heat treatments to produce various final dimensions. Composite wire production is illustrated using the example of a nickel/aluminum wire in the alloy ratio 80/20.