
Gadolinium is first purified (via solid-state methods, sublimation, etc.) and melted, then cast into ingots or round rod blanks. These serve as the raw material for both rod and wire production.

From the casting, a round rod of set diameter is cut out for further shaping. In rod production, this may already approach final size; in wire production, it becomes the starting billet.

- Rod: Often undergoes hot swaging, rolling, or extrusion to refine dimensions and achieve desired density.
- Wire: The cut round rod undergoes repeated hot swaging (typically reducing cross-sectional area by 10–50% per pass), with heat-preheating around 400–600 °C, until overall area reduction reaches ~90–97%—producing a finer-diameter wire core.

For specialized wire forms, the gadolinium core is inserted into a metal tube (e.g., copper, aluminum, nickel), after removing surface oxide (via acid wash or polishing), and then composite wire is integrated through drawing or swaging.

The wire undergoes drawing—likely using dies—to achieve very fine final diameters (down to sub-1 mm), ensuring uniformity, strength, and fine microstructure.

- Rod: May be polished to remove any surface oxidation and achieve smooth finish.
- Wire: After cladding or drawing, wires likewise may be polished to ensure clean surfaces and proper dimensional quality.

Final products are measured for tolerances, purity, and dimensional specs. Rods and wires are then vacuum-sealed or packaged under inert (e.g., argon) conditions, and labeled with documentation (like COA) to ensure quality and traceability.