Patent Publication Number: US-10760266-B2

Title: Varied length metal studs

Description:
BACKGROUND 
     Technical Field 
     The present disclosure relates to structural members, and more particularly, to metal studs. 
     Description of the Related Art 
     Metal studs and framing members have been used in the areas of commercial and residential construction for many years. Metal studs offer a number of advantages over traditional building materials, such as wood. For instance, metal studs can be manufactured to have strict dimensional tolerances, which increase consistency and accuracy during construction of a structure. Moreover, metal studs provide dramatically improved design flexibility due to the variety of available sizes and thicknesses and variations of metal materials that can be used. Moreover, metal studs have inherent strength-to-weight ratios which allow them to span longer distances and better resist and transmit forces and bending moments. 
     BRIEF SUMMARY 
     The various embodiments described herein may provide a stud with enhanced thermal efficiency over more conventional studs. While metals are typically classed as good thermal conductors, the studs described herein employ various structures and techniques to reduce conductive thermal transfer thereacross. For instance, use of a wire matrix, welds such as resistance welds, and specific weld locations such as at peaks, apexes, or intersections of the wires in the wire matrix, may contribute to the overall energy efficiency of the stud. 
     It has been found that light-weight metal studs incorporating a wire matrix can be strengthened, or in some cases their rigidity or stability and can be increased, such as to increase web crippling strengths of the ends of the studs, by fabricating the studs so that ends of the wires in the wire matrix are located at and/or welded to ends of channel members of the studs. 
     It has also been found that the ability to manufacture studs to any specific length provides distinct advantages, such as improving the efficiency of installation of the studs at a work site. Thus, systems and methods have been developed that allow the continuous fabrication of metal studs having various lengths and having ends of wires in a wire matrix located at and/or welded to ends of channel members of the studs. Such methods generally include continuously fabricating a wire matrix and stretching the wire matrix to various degrees corresponding to the various lengths of the studs to be fabricated, before welding the wire matrix to channel members. 
     A light-weight metal stud may be summarized as comprising: a first elongated channel member, the first elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the first elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective major face of the first elongated channel member, a respective first end along the major length thereof, and a respective second end along the major length thereof, the first end of the first elongated channel member opposite to the second end of the first elongated channel member across the major length of the first elongated channel member; a second elongated channel member, the second elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the second elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective major face of the second elongated channel member, a respective first end along the major length thereof, and a respective second end along the major length thereof, the first end of the second elongated channel member opposite to the second end of the second elongated channel member across the major length of the second elongated channel member; a first continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along the respective length thereof, and a respective second end along the respective length thereof, the first end of the first continuous wire member opposite to the second end of the first continuous wire member across the length of the first continuous wire member, the apexes of the first continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members, the first end of the first continuous wire member coupled to the first elongated channel member at the first end of the first elongated channel member, and the second end of the first continuous wire member coupled to either the first or the second elongated channel member at the second end of either the first or the second elongated channel member; and a second continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along the respective length thereof, and a respective second end along the respective length thereof, the first end of the second continuous wire member opposite to the second end of the second continuous wire member across the length of the second continuous wire member, the apexes of the second continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members, the first end of the second continuous wire member coupled to the second elongated channel member at the first end of the second elongated channel member, the second end of the second continuous wire member coupled to the second end of either the first or the second elongated channel member, and the first and the second elongated channel members held in spaced apart parallel relation to one another by both of the first and the second wire members, with a longitudinal passage formed therebetween. 
     The first and the second wire members may be physically attached to one another at each point at which the first and the second wire members cross one another. Each of the apexes of the second wire member may be opposed to a respective one of the apexes of the first wire member across the longitudinal passage. The first and the second continuous wires may be physically attached to the respective first flange of both the first and the second elongated channel member by welds and do not physically contact the respective major faces of the first and the second elongated channel members. The welds may be resistance welds. The apexes of the first continuous wire member attached to the first elongated channel member may alternate with the apexes of the second continuous wire member attached to the first elongated channel member such that a difference between a largest distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member and a smallest distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member is at least 1% of a mean distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member. The first and second continuous wire members may be plastically deformed wire members. The first and second continuous wire members may carry residual stresses. 
     A light-weight metal stud may be summarized as comprising: a first elongated channel member, the first elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the first elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective major face of the first elongated channel member; a second elongated channel member, the second elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the second elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective major face of the second elongated channel member; a first continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, the apexes of the first continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members; and a second continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, the apexes of the second continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members, the apexes of the first continuous wire member attached to the first elongated channel member alternating with the apexes of the second continuous wire member attached to the first elongated channel member such that a difference between a largest distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member and a smallest distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member is at least 1% of a mean distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member, the first and the second elongated channel members held in spaced apart parallel relation to one another by both of the first and the second wire members, with a longitudinal passage formed therebetween. 
     A difference between a largest distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member and a smallest distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member may be at least 2%, 3%, or 5% of a mean distance between adjacent ones of the apexes of the first and second continuous wires attached to the first elongated channel member. 
     A method of making a light-weight metal stud may be summarized as comprising: providing a first elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the first elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective major face of the first elongated channel member; providing a second elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the second elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective major face of the second elongated channel member; tensioning a wire matrix including first and second continuous wire members, each of the first and second wire members having a plurality of bends to form alternating apexes along a respective length thereof; and coupling the first and the second elongated channel members together with the tensioned wire matrix, the apexes of the first continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members, and the apexes of the second continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members. 
     The method may further comprise physically attaching the first and the second continuous wire members to one another at intersection points thereof. The physically attaching the first and the second continuous wire members to one another at intersection points thereof may occur before the coupling the first and the second elongated channel members together by the wire matrix. Tensioning the wire matrix may include tensioning the wire matrix along a longitudinal axis of the wire matrix. Tensioning the wire matrix may include plastically and/or elastically deforming the wire matrix. 
     A plurality of studs may be summarized as comprising: a first light weight stud having a first length, the first stud including: a first elongated channel member, the first elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the first elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective major face of the first elongated channel member, a respective first end along the major length thereof, and a respective second end along the major length thereof, the first end of the first elongated channel member opposite to the second end of the first elongated channel member across the major length of the first elongated channel member; a second elongated channel member, the second elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the second elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective major face of the second elongated channel member, a respective first end along the major length thereof, and a respective second end along the major length thereof, the first end of the second elongated channel member opposite to the second end of the second elongated channel member across the major length of the second elongated channel member; a first continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along the respective length thereof, and a respective second end along the respective length thereof, the first end of the first continuous wire member opposite to the second end of the first continuous wire member across the length of the first continuous wire member, the apexes of the first continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members, the first end of the first continuous wire member coupled to the first end of the first elongated channel member, and the second end of the first continuous wire member coupled to the second end of either the first or the second elongated channel member; and a second continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along the respective length thereof, and a respective second end along the respective length thereof, the first end of the second continuous wire member opposite to the second end of the second continuous wire member across the length of the second continuous wire member, the apexes of the second continuous wire member alternatively physically attached to the first and the second elongated channel members along at least a portion of the first and the second elongated channel members, the first end of the second continuous wire member coupled to the first end of the second elongated channel member, the second end of the second continuous wire member coupled to the second end of either the first or the second elongated channel member, the apexes of the first continuous wire member attached to the first elongated channel member spaced apart from adjacent apexes of the second continuous wire member attached to the first elongated channel member by a first pitch, and the first and the second elongated channel members held in spaced apart parallel relation to one another by both of the first and the second wire members, with a longitudinal passage formed therebetween; and a second light weight stud having a second length, the second stud including: a third elongated channel member, the third elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the third elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective major face of the third elongated channel member, a respective first end along the major length thereof, and a respective second end along the major length thereof, the first end of the third elongated channel member opposite to the second end of the third elongated channel member across the major length of the third elongated channel member; a fourth elongated channel member, the fourth elongated channel member having a respective major face having a respective first edge along a major length thereof and a respective second edge along the major length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective major face of the fourth elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective major face of the fourth elongated channel member, a respective first end along the major length thereof, and a respective second end along the major length thereof, the first end of the fourth elongated channel member opposite to the second end of the fourth elongated channel member across the major length of the fourth elongated channel member; a third continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along the respective length thereof, and a respective second end along the respective length thereof, the first end of the third continuous wire member opposite to the second end of the third continuous wire member across the length of the third continuous wire member, the apexes of the third continuous wire member alternatively physically attached to the third and the fourth elongated channel members along at least a portion of the third and the fourth elongated channel members, the first end of the third continuous wire member coupled to the first end of the third elongated channel member, and the second end of the third continuous wire member coupled to the second end of either the third or the fourth elongated channel member; and a fourth continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along the respective length thereof, and a respective second end along the respective length thereof, the first end of the fourth continuous wire member opposite to the second end of the fourth continuous wire member across the length of the fourth continuous wire member, the apexes of the fourth continuous wire member alternatively physically attached to the third and the fourth elongated channel members along at least a portion of the third and the fourth elongated channel members, the first end of the fourth continuous wire member coupled to the first end of the fourth elongated channel member, the second end of the fourth continuous wire member coupled to the second end of either the third or the fourth elongated channel member, the apexes of the third continuous wire member attached to the third elongated channel member spaced apart from adjacent apexes of the fourth continuous wire member attached to the third elongated channel member by a second pitch, and the third and the fourth elongated channel members held in spaced apart parallel relation to one another by both of the third and the fourth wire members, with a longitudinal passage formed therebetween; wherein the first length differs from the second length and the first pitch differs from the second pitch. 
     The first length may differ from the second length by an amount that is not a multiple of either the first pitch or the second pitch. The first length may differ from the second length by 1 inch. The first length may differ from the second length by less than ½ inch. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings. 
         FIG. 1A  is an isometric view of a metal stud, according to at least one illustrated embodiment. 
         FIG. 1B  is an enlarged partial view of the isometric view of a metal stud of  FIG. 1A , according to at least one illustrated embodiment. 
         FIG. 2  is a schematic view of a wire matrix of the metal stud of  FIG. 1A , according to at least one illustrated embodiment. 
         FIG. 3  is a cross-sectional view of a portion of the metal stud of  FIG. 1A , taken along line  3 - 3  in  FIG. 1A , according to at least one illustrated embodiment. 
         FIG. 4  is an isometric environmental view showing the metal stud of  FIG. 1A  adjacent a wall, according to at least one illustrated embodiment. 
         FIG. 5A  is a schematic view of a wire matrix of the metal stud of  FIG. 1A  in an un-tensioned or an un-stretched configuration, according to at least one illustrated embodiment. 
         FIG. 5B  is a schematic view of the wire matrix of  FIG. 5A  in a tensioned or a stretched configuration, according to at least one illustrated embodiment. 
         FIG. 5C  is a schematic view of the wire matrix as illustrated in  FIG. 5A  overlaid with the wire matrix as illustrated in  FIG. 5B , according to at least one illustrated embodiment. 
         FIG. 6  is a schematic view of an assembly line for fabricating a plurality of varied-length metal studs, according to at least one illustrated embodiment. 
         FIG. 7  is a top plan view of a reinforcement plate in a folded configuration, according to at least one illustrated embodiment. 
         FIG. 8  is a front elevational view of the reinforcement plate of  FIG. 7  in the folded configuration. 
         FIG. 9  is a right side elevational view of the reinforcement plate of  FIG. 7  in the folded configuration. 
         FIG. 10  is an isometric view of the reinforcement plate of  FIG. 7  in the folded configuration. 
         FIG. 11  is a top plan view of the reinforcement plate of  FIG. 7  in a flattened configuration, prior to being folded to form upstanding portions or tabs. 
         FIG. 12  is a top isometric view of a metal framing member including a metal stud and reinforcement plate physically coupled thereto proximate at least one end thereof, according to at least one illustrated embodiment. 
         FIG. 13  is a bottom isometric view of the metal framing member of  FIG. 12 . 
         FIG. 14  is an end elevational view of the metal framing member of  FIG. 12 . 
         FIG. 15  is a bottom view of the metal framing member of  FIG. 12 . 
         FIG. 16  is a cross-sectional view of the metal framing member of  FIG. 12 , taken along the section line A-A of  FIG. 15 . 
         FIG. 17  is a cross-sectional view of two sheets of material having been coupled to one another by swaging or radially cold expanding a bushing assembly. 
         FIG. 18  is a cross-sectional view of two sheets of material having been coupled to one another by a rivet. 
         FIG. 19A  is a cross-sectional view of two sheets of material to be clinched or press joined to one another. 
         FIG. 19B  is a cross-sectional view of the two sheets of material of  FIG. 19A , having been clinched or press joined to one another. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with the technology have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. 
     Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprising” is synonymous with “including,” and is inclusive or open-ended (i.e., does not exclude additional, un-recited elements or method acts). 
     Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
     As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its broadest sense, that is, as meaning “and/or” unless the context clearly dictates otherwise. 
     The headings and Abstract of the Disclosure provided herein are for convenience only and do not limit the scope or meaning of the embodiments. 
       FIG. 1A  shows a light-weight metal stud  10  according to one aspect of the present disclosure. The stud  10  includes a first elongated channel member  12  and a second elongated channel member  14  positioned at least approximately parallel to and spatially separated from each other. A wire matrix  16  is coupled to and positioned between the first elongated channel member  12  and the second elongated channel member  14  at various portions along the lengths of the members. 
     As illustrated in  FIG. 1B , the wire matrix  16  may be comprised of a first angled continuous wire  18  and a second angled continuous wire  20  coupled to each other ( FIG. 2 ). The first and second angled continuous wires  18 ,  20  may each be a continuous piece of metal wire. The first angled continuous wire  18  includes a plurality of bends that form a plurality of first apexes  22  that successively and alternately contact the first elongated channel member  12  and the second elongated channel member  14 . Likewise, the second angled continuous wire  20  may include a plurality of bends that form a plurality of second apexes  24  to successively and alternately contact the first elongated channel member  12  and the second elongated channel member  14  ( FIG. 3 ). The wire matrix  16  may be formed by overlaying the first angled continuous wire  18  onto the second angled continuous wire  20  and securing the wires to each other, for example with a series of welds or resistance welds, thereby forming a series of intersection points  26  positioned between the first and second elongated channel members  12 ,  14 . 
     The wire matrix  16  may be secured to the first and second elongated channel members  12 ,  14  at all first and second apexes  22 ,  24  such that the first apexes  22  alternate with the second apexes  24  along at least a portion of a length of the first elongated channel member  12  and along at least a portion of a length of the second elongated channel member  14 . Accordingly, a series of longitudinal passages  28  are formed along a central length of the wire matrix  16 . The longitudinal passages  28  may be quadrilaterals, for instance diamond-shaped longitudinal passages. The longitudinal passages  28  may be sized to receive utilities, for example wiring, wire cables, fiber optic cable, tubing, pipes, other conduit. 
     The first and second angled continuous wires  18 ,  20  may each have any of a variety of cross-sectional profiles. Typically, first and second angled continuous wires  18 ,  20  may each have a round cross-sectional profile. Such may reduce materials and/or manufacturing costs, and may advantageously eliminate sharp edges which might otherwise damage utilities (e.g., electrically insulative sheaths). Alternatively, the first and second angled continuous wires  18 ,  20  may each have cross-sectional profiles of other shapes, for instance a polygonal (e.g., rectangular, square, hexagonal). Where a polygonal cross-sectional profile is employed, it may be advantageous to have rounded edges or corners between at least some of the polygonal segments. Again, this may eliminate sharp edges which might otherwise damage utilities (e.g., electrically insulative sheaths). Further, the second angled continuous wire  20  may have a different cross-sectional profile from that of the first angled continuous wire  18 . 
       FIG. 2  shows the particular configuration of a wire matrix  16  of the stud  10  shown in  FIG. 1A  according to one aspect. The wire matrix  16  includes a first angled continuous wire  18  overlying a second angled continuous wire  20 , which is shown in dashed lines for purposes of illustration. This illustration shows that each of the first and second angled continuous wires  18 ,  20  extend between both of the first and second elongated channel members  12 ,  14  in an overlapping manner such that a length of each first and second angled continuous wires  18 ,  20  extends from one elongated channel member to the other elongated channel member in an alternating manner ( FIG. 3 ). Accordingly, the first angled continuous wire  18  includes a plurality of apexes  22   a  and  22   b  on either side of the first angled continuous wire  18 , and the second angled continuous wire  20  includes a plurality of apexes  24   a  and  24   b  on either side of the second angled continuous wire  20  for attachment to both of the first and second elongated channel members  12 ,  14 . 
       FIG. 3  shows a portion of a front cross-sectional view of the stud  10  taken along lines  3 - 3  in  FIG. 1A . The first elongated channel member  12  and the second elongated channel member  14  are shown positioned parallel to and spatially separated from each other with the wire matrix  16  coupling the elongated channel members  12 ,  14  to each other. The first angled continuous wire  18  is formed with a plurality of bends that form a plurality of first apexes  22   a ,  22   b  that successively and alternately contact the first elongated channel member  12  and the second elongated channel member  14 . Likewise, the second angled continuous wire  20  is formed with a plurality of bends that form a plurality of second apexes  24   a ,  24   b  to successively and alternately contact the first elongated channel member  12  and the second elongated channel member  14 . 
     The wire matrix  16  may be formed by overlying the first angled continuous wire  18  onto the second angled continuous wire  20  and securing the wires to each other with a series of welds, such as resistance welds, thereby forming a series of intersection points  26  positioned between the first and second elongated channel members  12 ,  14 . The wire matrix  16  may be secured to the first and second elongated channel members  12 ,  14 , such as by welds such as resistance welds, at all first and second apexes  22   a ,  22   b ,  24   a ,  24   b  such that the first apexes  22   a  alternate with the second apexes  24   a  along a length the first elongated channel member  12 , and the first apexes  22   b  alternate with the second apexes  24   b  along a length second elongated channel member  14 . Accordingly, a series of longitudinal passages  28  are formed along a longitudinal length of the wire matrix  16 . The longitudinal passages  28  have a profile that is substantially separate from the first and second elongated channel members  12 ,  14 . As such, the longitudinal passages  28  may act as a shelf to support and receive utility lines or other devices ( FIG. 4 ). 
     Where the stud  10  is installed vertically, the first and second angled continuous wires  18 ,  20  will run at oblique angles to the ground and a gravitational vector (i.e., the direction of a force of gravity), that is, be neither horizontal nor vertical. Thus, the portions of the first and second angled continuous wires  18 ,  20  which form each of the longitudinal passages  28  are sloped or inclined with respect to the ground. Utilities installed or passing through a longitudinal passage  28  will tend, under the force of gravity, to settle into a lowest point or valley in the longitudinal passage  28 . This causes the utility to be at least approximately centered in the stud  10 , referred to herein as self-centering. Self-centering advantageously moves the utility away from the portions of the stud to which wallboard or other materials will be fastened. Thus, self-centering helps protect the utilities from damage, for instance damage which might otherwise be caused by the use of fasteners (e.g., screws) used to fasten wallboard or other materials to the stud  10 . 
     The first elongated channel member  12  may have a major face or web  30  and a first flange  32 . Likewise, the second elongated channel member  14  may have a major face or web  34  and a first flange  36  ( FIG. 3 ). The wire matrix  16  may be coupled to the flanges  32 ,  36  periodically along a length of the first and second elongated channel members  12 ,  14 . In some aspects, the first apexes  22   a ,  24   a  may be coupled to the first flange  32  of the first elongated channel member  12  and spatially separated from the major face  30  by a distance L. Likewise, the second apexes  22   b ,  24   b  may be coupled to the first flange  36  of the second elongated channel member  14  and spatially separated from the major face  34  by a distance L. 
     The distance L in any aspect of the present disclosure can vary from a very small to a relatively large distance. In some configurations, distance L is less than one half of an inch, or less than one quarter of an inch, although distance L can vary beyond such distances. Spatially positioning the apexes from the major faces  30 ,  34  of the elongated channel members  12 ,  14  provides one advantage of reducing manufacturing operations and improving consistency of the size and shape of the stud because the elongated channel members can be positioned and secured to the wire matrix relative to each other, as opposed to relative to the shape and size of the wire matrix, which may vary, e.g., due to manufacturing tolerances, between applications. 
     According to some aspects, the apexes  22  and the apexes  24  laterally correspond to each other as coupled to respective first and second elongated channel members  12 ,  14 . For example, the first apexes  22   a  may be opposed, for instance diametrically opposed, across a longitudinal axis  38  of the stud  10  from the second apexes  24   b  along a length the first elongated channel members  12 ,  14 . For example, apex  22   a  is positioned at a contact portion of the first elongated channel member  12  that corresponds laterally to the position of the apex  24   b  on the second elongated channel member  14 . The same holds true for apex  24   a  and apex  22   b , as best illustrated in  FIG. 3 . The plurality of first and second apexes  22 ,  24  extend along the length of the stud  10  and are coupled successively and alternately to the first and second elongated channel members  12 ,  14 . As illustrated in  FIGS. 2 and 3 , the first and second angled continuous wires  18  and  20  can be mirror images of one another across a central longitudinal axis  38  that extends along the length of the stud  10  and through the center of the stud  10  in a direction parallel to the lengths of the first and second elongated channel members  12  and  14 , such that the wire matrix  16  is symmetrical about the axis  38 . In other embodiments, the wire matrix  16  is not symmetrical about the axis  38 . 
     The first angled continuous wire  18  has an apex  22   b  coupled to the second elongated channel member  14 , while the second angled continuous wire  20  has an apex  24   b  coupled to the second elongated channel member  14  adjacent apex  22   b  and spaced apart from apex  22   b  by a distance or pitch P. Pitch P can be a given distance less than ten inches, or less than eight inches, although the given distance can vary beyond such distances. The first and second angled continuous wires  18 ,  20  may be bent at an angle X, as shown near the apex  22   a  and apex  24   b . Angle X can be between approximately 60 and 120 degrees, or approximately 90 degrees, or between approximately 30 and 60 degrees, or approximately 45 degrees, although angle X could vary beyond such values and ranges. Angle X has a corresponding relationship to pitch P. Thus, the continuous wires  18 ,  20  could be formed at a relatively small angle X (less than 30 degrees), which reduces the distance of pitch P, which can increase strength of the stud  10  for particular applications. 
       FIG. 4  shows a stud system  100  having a pair of light-weight metal studs according to one aspect of the present disclosure. The system  100  includes a first stud  10  and a second stud  10 ′ positioned spatially apart from each other and against a wall  48 , as with typical structural arrangements. The first stud  10  and the second stud  10 ′ each include a first elongated channel member  12  and a second elongated channel member  14  positioned parallel to and spatially separated from each other. The first stud  10  includes a wire matrix  16  coupled to and positioned between the first elongated channel member  12  and the second elongated channel member  14  at various portions along the lengths of the members, such as described with reference to  FIGS. 1-3 . The second stud  10 ′ includes a wire matrix  116  coupled to and positioned between the first elongated channel member  12  and the second elongated channel member  14  at various portions along the length of the elongated channel members, such as described with reference to  FIGS. 1-3 . 
     The wire matrices  16  and  116  of the studs  10  and  10 ′, respectively, each define a plurality of longitudinal passages  28  and  128 , respectively, along a central length of the wire matrices  16  and  116 . The longitudinal passages  28  and  128  may partially or completely structurally support utility lines, such as an electrical wire  52  and a pipe  50 . Additionally, the longitudinal passages  28  and  128  allow egress of utility lines to physically separate the utility lines from each other and away from sharp edges of the first and second elongated channel members  12 ,  14  to reduce or prevent damage to the lines and to increase safety. 
     As illustrated in  FIGS. 1A, 3, and 4 , the studs  10  and  10 ′ and the elongated channel members  12  and  14  can have respective first ends, such as along the axis  38 , and respective second ends, such as opposed to the first ends along the axis  38 . The first and second angled continuous wires  18  and  20  have respective first ends welded to the first ends of the studs  10  and  10 ′ and the first ends of the elongated channel members  12  and  14 , and respective second ends welded to the second ends of the studs  10  and  10 ′ and the second ends of the elongated channel members  12  and  14 . In some cases, the first and second ends of the first and second angled continuous wires  18  and  20  can coincide with apexes (e.g., apexes  22   a  and  24   b  or apexes  22   b  and  24   a ) of the first and second angled continuous wires  18  and  20  to within the range of 0.010 inches. 
     In some methods of manufacturing a metal stud such as the stud  10 , a wire matrix such as the wire matrix  16  can be fabricated as described above, and can then be tensioned or stretched along its length, which can involve elastically, plastically, or a combination of elastically and plastically stretching the wire matrix, and which can involve temporarily or permanently increasing the length of the wire matrix, as described further below, before being coupled to first and second elongated channel members such as channel members  12  and  14 . For example,  FIG. 5A  is a schematic view of the wire matrix  16  in an un-tensioned or an un-stretched configuration, illustrating the first angled continuous wire  18  and the second angled continuous wire  20 , as well as their intersection points  26  and the longitudinal passages  28  they form.  FIG. 5B  is a schematic view of the wire matrix  16  in a modified, tensioned, or stretched configuration, indicated by reference numeral  16   a , including the first angled continuous wire  18  in a modified, tensioned, or stretched configuration, indicated by reference numeral  18   a , and the second angled continuous wire  20  in a modified, tensioned, or stretched configuration, indicated by reference numeral  20   a , as well as their intersection points  26   a  and the longitudinal passages  28   a  they form. 
       FIG. 5C  is a schematic view of the un-stretched wire matrix  16 , as illustrated in  FIG. 5A , overlaid with the stretched wire matrix  16   a , as illustrated in  FIG. 5B . As shown in  FIGS. 5A-5C , a stretching operation performed on the wire matrix  16  can change several dimensions and features of the wire matrix  16 , while leaving other dimensions and features unchanged. As an example,  FIGS. 5A and 5B  illustrate that the first angled continuous wire  18  includes a plurality of linear sections extending between and interconnecting its apexes  22   a  and  22   b , and that the second angled continuous wire  20  includes a plurality of linear sections extending between and interconnecting its apexes  24   a  and  24   b . As illustrated in  FIGS. 5A and 5B , each of these linear sections has a length of L 1  in the un-stretched wire matrix  16 , and a length of L 1a  in the stretched wire matrix  16   a . L 1  is the same as or equal to L 1a , reflecting the fact that the stretching operation does not change the lengths of these individual linear sections. 
     As another example, as also illustrated in  FIGS. 5A-5C , the first and second angled continuous wires  18  and  20  may be bent at an angle X in the un-stretched configuration, while the first and second angled continuous wires  18   a  and  20   a  may be bent at an angle X a  in the stretched configuration, where the angle X a  is greater than the angle X by an angle difference X d  (note one half of angle X d  is illustrated in  FIG. 5C ). As another example, as also illustrated in  FIGS. 5A-5C , adjacent apexes of the first and second angled continuous wires  18  and  20 , e.g., adjacent apexes  22   a  and  24   a , or adjacent apexes  22   b  and  24   b , are spaced apart from one another by a distance or pitch P in the un-stretched configuration, while adjacent apexes of the first and second angled continuous wires  18   a  and  20   a  are spaced apart from one another by a distance or pitch P a  in the stretched configuration, where the pitch P is less than the pitch P a  by a pitch difference P d . 
     As another example, as also illustrated in  FIGS. 5A-5C , the wire matrix  16  has an overall length L 2  in the un-stretched configuration, while the wire matrix  16   a  has an overall length L 2a  in the stretched configuration, where the length L 2  is less than the length L 2a  by a length difference L 2d . As another example, as also illustrated in  FIGS. 5A-5C , the wire matrix  16  has an overall width Win the un-stretched configuration, while the wire matrix  16   a  has an overall width W a  in the stretched configuration, where the width W is greater than the width W a  by a width difference W d  (note one half of width difference W d  is illustrated in  FIG. 5C ). 
     These features and dimensions are geometrically inter-related with one another. For example, as the wire matrix  16  is longitudinally stretched, the pitch P and the overall length L 2  increase linearly with one another (i.e., a ratio of P d  to L 2d  remains constant throughout a stretching operation) in accordance with the degree of stretching. Further, as the wire matrix  16  is longitudinally stretched, and therefore as the pitch P and the length L 2  increase, the angle X increases and the width W decreases in accordance with the degree of stretching and the geometric relationships of the various components. Thus, longitudinal stretching of the wire matrix  16  increases the distance L (see  FIG. 3 ) for a given spacing between the first and second elongated channel members  12  and  14 . As noted above, the length L 1  remains constant or unchanged over the course of a stretching operation as the wire matrix  16  is stretched. 
       FIG. 6  is a schematic view of an assembly line  200  for fabricating a plurality of varied-length metal studs or an individual stud having any specified width and any specified length, including any standard or non-standard width and length. For example, the assembly line  200  can be used to fabricate a plurality of metal studs having respective lengths that differ from one another by increments that are less than a pitch of the wire matrix of the studs, such as by 4 inches or less, 3 inches or less, 2 inches or less, 1 inch or less, ½ inch or less, ¼ inch or less, ⅛ inch or less, 1/16 inch or less, or by any desired increment. 
     As illustrated in  FIG. 6 , the assembly line  200  can include one or more, e.g., one or two, zig-zag wire benders or formers  202 . The zig-zag wire benders  202  can take standard, off-the-shelf linear wire as input and output two zig-zag wires  204 , from which a plurality of angled continuous wires, such as the first and second angled continuous wires  18  and  20 , can eventually be singulated and formed. Thus, the zig-zag wires  204  can have structures matching the structures of the first and second angled continuous wires  18  and  20 , as described above, but in a continuous form. 
     The assembly line  200  can also include a first welding system  206 , which can include a plurality of spring-loaded pins  234  carried by a moving conveyor  236 , and a rotary resistance welding system  238 . The first welding system  206  can accept the two zig-zag wires  204  as input and synchronize the movement of the two zig-zag wires  204  by engaging the pins  234  with apexes of the zig-zag wires  204  and pulling the zig-zag wires  204  taut so that the apexes of the zig-zag wires  204  are spaced apart from one another by a nominal pitch (e.g., as discussed further below). The first welding system  206  can also weld (e.g., resistance weld) the two zig-zag wires  204  to one another at their intersection points, such as by using the rotary resistance welding system  238 , thereby forming a continuous wire matrix  208 . The zig-zag wires  204  and the continuous wire matrix  208  are illustrated in  FIG. 6  as being oriented vertically and within the page for purposes of illustration, although in practice, the zig-zag wires  204  and the continuous wire matrix  208  are oriented horizontally and into the page. 
     The continuous wire matrix  208  can be a continuous wire matrix from which a plurality of individual wire matrices such as the wire matrix  16  can eventually be singulated and formed. Thus, the continuous wire matrix  208  can have a structure matching the structure of the wire matrix  16 , but in a continuous form. For example, the continuous wire matrix  208  can have a nominal, or un-stretched pitch corresponding to the pitch P illustrated in  FIG. 5A , and a nominal, or un-stretched width corresponding to the width W illustrated in  FIG. 5A . It has been found that using a continuous wire matrix  208  having a consistent nominal pitch of about 6 inches to fabricate metal studs having a variety of specified overall lengths and widths, and using a continuous wire matrix  208  having a nominal width that varies based on the specified overall widths of the metal studs to be fabricated, is advantageous. 
     The assembly line  200  can also include an expanding mandrel pitch spacing mechanism, which can be referred to as a first, upstream conveyor  210 . The first, upstream conveyor  210  can include a plurality of radially extending pins  212 , a first encoder  214 , and a plurality of expanding mandrel segments  218  that can ride radially inward and outward along the pins  212  between an inner position, designated by reference numeral  218   a  and in which the expanding mandrel segments  218  have a length of 6 inches, and an outer position, designated by reference numeral  218   b  and in which the expanding mandrel segments  218  have a length of 6⅜ inches. The radial positions of the expanding mandrel segments  218  can be adjusted along the pins  212  to alter the lengths of the expanding mandrel segments  218  between the respective pins  212 , so that the lengths of the expanding mandrel segments  218  match the nominal pitch of the continuous wire matrix  208 , and so that the continuous wire matrix  208  can be positioned against the expanding mandrel segments  218  as the continuous wire matrix passes over the first, upstream conveyor  210 . 
     As the continuous wire matrix  208  passes over the first conveyor  210 , the pins  212  can engage with the continuous wire matrix  208 , such as by extending through the longitudinal passages extending through the continuous wire matrix  208  and thereby engaging with the welded intersections of the continuous wire matrix  208  or with the apexes of the zig-zag wires  204 , to meter the rate at which the continuous wire matrix  208  exits the first conveyor  210  and to prevent the continuous wire matrix  208  from exiting the first conveyor  210  more quickly than desired. In some cases, this can include applying a force to the continuous wire matrix  208 , e.g., to the welded intersections of the continuous wire matrix  208  or to the apexes of the zig-zag wires  204 , in a direction opposite to the direction the continuous wire matrix  208  travels through the first conveyor  210  and through the assembly line  200 . In other implementations, the first conveyor  210  can engage with the continuous wire matrix  208  by other techniques, such as those described below for the second conveyor  226 . 
     The zig-zag wire benders  202 , the first welding system  206 , and the first conveyor  210  can be arranged on a first processing line  240  which can be on an elevated mezzanine level on a factory floor. Continuous elongated channel members  216  can be formed by a sheet metal roll former located below the elevated mezzanine level on the factory floor, and can be introduced and metered into the assembly line  200  along a second processing line  242 , located below the elevated mezzanine level on the factory floor, that runs in parallel to and below the first processing line  240 . In alternative implementations, the second processing line  242  can run above or at the same elevation as and to the side of the first processing line  240 , rather than below the first processing line  240 . A plurality of individual elongated channel members such as the first and second elongated channel members  12  and  14  can eventually be singulated and formed from the continuous elongated channel members  216 . Thus, the continuous elongated channel members  216  can have a structure matching the structure of the first and second elongated channel members  12  and  14 , but in a continuous form. 
     The assembly line  200  can also include a plurality of rollers  220  arranged to extend from a last one of the rollers  220  nearest to a second welding system  222 , which can be a resistance welding system, and which is described further below, and in the second processing line  242 , away from the second welding system  222  and toward the first processing line  240 , that is, to extend upstream with respect the assembly line  200  and upward away from the continuous elongated channel members  216 . Together, the first conveyor  210  and the plurality of rollers  220  form an S-shaped conveyor that precisely guides the continuous wire matrix  208  along a constant-length path and with minimal friction to reduce changes to the degree to which the continuous wire matrix  208  is tensioned or stretched, from the first processing line  240  to the second processing line  242 . 
     The continuous wire matrix  208  travels over the first conveyor  210  and under the plurality of rollers  220  from the first conveyor  210  to the second welding system  222 , from the first processing line  240  into the second processing line  242 , and into physical proximity or engagement with the continuous elongated channel members  216 . The assembly line  200  then carries the continuous wire matrix  208  and the continuous elongated channel members  216  into the second welding system  222 , which can include a dual-station rotary welding system having powered and spring-loaded wheels to create a welding pressure to weld (e.g., resistance weld) apexes of the continuous wire matrix  208  to flanges of the continuous elongated channel members  216 . The second welding system  222  can weld (e.g., resistance weld) the continuous wire matrix  208  to the continuous elongated channel members  216 , to form a continuous elongate metal stud  228 . 
     In doing so, the wheels of the second welding system  222  can engage with the continuous elongated channel members  216  to weld the continuous wire matrix  208  thereto, without contacting the continuous elongate channel members  216  in locations where the continuous wire matrix  208  is not to be welded thereto. Thus, contact between the wheels of the second welding system  222  and the continuous elongated channel members  216  and the continuous wire matrix  208  is intermittent. A plurality of elongate metal studs, such as metal stud  10 , can eventually be singulated and formed from the continuous elongate metal stud  228 . Thus, the continuous elongate metal stud  228  can have a structure matching the structure of the metal stud  10 , as described above, but in a continuous form. 
     The assembly line  200  also includes a second encoder  224  and a second, downstream conveyor  226 , which can include a plurality of pull rolls that engage the continuous elongate metal stud  228 , e.g., engage flanges of the continuous elongated channel members  216  of the continuous elongate metal stud  228  frictionally or otherwise mechanically, or by other techniques, such as those described above for the first conveyor  210 , and meter the rate at which the continuous elongate metal stud  228  exits the second conveyor  226 , and to prevent the continuous elongate metal stud  228  from exiting the second conveyor  226  more slowly than desired. In some cases, this can include applying a force to the continuous elongate metal stud  228  in a direction aligned with the direction the continuous elongate metal stud  228  travels through the second conveyor  226  and through the assembly line  200 . 
     Thus, the first conveyor  210  can act to hold the continuous wire matrix  208  back as it travels through the assembly line  200  (e.g., it can apply a force to the continuous wire matrix  208  that acts in a direction opposite to its direction of travel, i.e., in an upstream direction), while the second conveyor  226  can act to pull the continuous elongate metal stud  228 , and thus the wire matrix  208 , forward as they travel through the assembly line  200  (e.g., it can apply a force to the continuous elongate metal stud  228  that acts in a direction aligned with its direction of travel, i.e., in an downstream direction). Thus, together, the first conveyor  210  and the second conveyor  226  can apply tension to the continuous wire matrix  208  such that the continuous wire matrix  208  is stretched, either elastically or plastically, between the first conveyor  210  and the second conveyor  226 , and held in a tensioned or stretched configuration as it is welded (e.g., resistance welded) to the continuous elongated channel members  216 . This can be referred to as “pre-tensioning” the continuous wire matrix  208 . 
     As a result of the stretching, the continuous wire matrix  208  can travel through the first processing line  240  at a first speed, which can be constant throughout the first processing line  240 , and through the second processing line  242  at a second speed, which can be constant throughout the second processing line  242 . In some cases, such as when the continuous wire matrix  208  is to be stretched, the second speed is greater than the first speed. In other cases, such as when the continuous wire matrix  208  is not to be stretched, the second speed is the same as the first speed. The first and the second speeds can be between 200 and 300 feet per minute. 
     Further, by controlling a rate at which the first conveyor  210  meters the continuous wire matrix  208 , and by controlling a rate at which the second conveyor  226  meters the continuous elongate metal stud  228 , the tension developed in the continuous wire matrix  208 , and a degree to which the continuous wire matrix  208  is stretched, can be precisely controlled. For example, after being stretched, the continuous wire matrix  208  can have a stretched pitch corresponding to the pitch P a  illustrated in  FIG. 5B , which is typically greater than the nominal pitch of about 6 inches by the pitch difference P d  illustrated in  FIG. 5C , and a stretched width corresponding to the width W a  illustrated in  FIG. 5B , which is typically greater than the nominal width by the width difference W d  illustrated in  FIG. 5C . In some implementations, the pitch difference P d  can be anywhere from 0 inches up to at least ⅜ inch. 
     During operation of the assembly line  200 , the first encoder  214  can measure a length of the continuous wire matrix  208  metered out by the first conveyor  210 , such as by counting a number of the welded intersections of the wires of the wire matrix  208  that pass over the first conveyor  210 . During operation of the assembly line  200 , the second encoder  224  can measure a length of the continuous wire matrix  208  metered into the second conveyor  226 , such as by measuring a length of the continuous elongate metal stud  228  entering into the second conveyor  226 . In some cases, the encoders  214  and  224  can be reset every time a length material corresponding to an individual metal stud is measured by the encoder  214  or  224 , respectively, to reduce or eliminate the accumulation of measurement errors across a large number of studs. 
     An output of the first encoder  214  can be compared to an output of the second encoder  224  to check that the continuous wire matrix  208  is being stretched to a specified degree. If the comparison of these outputs reveals that the continuous wire matrix  208  is being stretched to the specified degree, then no corrective action can be taken. If the comparison of these outputs reveals that the continuous wire matrix  208  is being stretched to more than the specified degree, then corrective action can be taken to speed up the first processing line  240  or slow down the second processing line  242 . If the comparison of these outputs reveals that the continuous wire matrix  208  is being stretched to less than the specified degree, then corrective action can be taken to slow down the first processing line  240  or speed up the second processing line  242 . 
     The assembly line  200  can also include a laser scanning system  230 , which can scan the continuous elongate metal stud  228  as it exits the second conveyor  226 . For example, the laser scanner  230  can scan the continuous elongate metal stud  228  and measure the distance between adjacent welded intersections of the wires of the wire matrix  208 . Such distances can be averaged over a length of the continuous elongate metal stud  228  that corresponds to a length of an individual stud to be singulated from the continuous elongate metal stud  228 , which average can then be compared to a desired average pitch for the individual stud. 
     If this comparison reveals that the continuous wire matrix  208  is being stretched to the specified degree, then no corrective action can be taken. If this comparison reveals that the continuous wire matrix  208  is being stretched to more than the specified degree, then corrective action can be taken to speed up the first processing line  240  or slow down the second processing line  242 . If this comparison reveals that the continuous wire matrix  208  is being stretched to less than the specified degree, then corrective action can be taken to slow down the first processing line  240  or speed up the second processing line  242 . 
     The assembly line  200  can also include a flying shear cutting system  232 , which can shear or cut the continuous elongate metal stud  228  in order to singulate and form a plurality of individual metal studs, such as metal stud  10 , from the continuous elongate metal stud  228 . Actuation of the flying shear cutting system  232  to cut the continuous elongate metal stud  228  can be triggered by a signal provided by the laser scanner  230  that signifies that a desired or specified number of welded intersections of the wires of the wire matrix  208  have passed by the laser scanner  230 . 
     Upon receipt of such a signal from the laser scanner  230 , the flying shear cutting system  232  can accelerate a cutting unit thereof from a home position in the direction of travel of the continuous elongate metal stud  228  until a speed of the cutting unit matches the speed of the continuous elongate metal stud  228 , at which point, the cutting unit can be actuated to cut the continuous elongate metal stud  228 . The cutting unit can then be decelerated to a stop and then returned to its home position. A position of the laser scanner  230  can be adjusted and calibrated experimentally during commissioning of the assembly line  200  until the cutting unit cuts the continuous elongate metal stud  228  at apexes of the wire matrix  208  to within an accuracy of 0.010 inches. Using the features described herein, errors affecting this accuracy are not cumulative and thus the accuracy can remain constant throughout production. In some cases, such adjusting and calibrating can be performed with a continuous elongate metal stud  228  having a wire matrix  208  with a pitch of 6 inches, and the laser scanner  230  can be mounted on a servo-driven positioner so that the laser scanner  230  can be moved and adjusted as needed during operation of the assembly line  200  to ensure that the cutting unit cuts individual metal studs having wire matrices of different pitches at apexes of the wire matrices. 
     A method of using the assembly line  200  to fabricate a metal stud, such as the metal stud  10 , to have a specified overall width W s , e.g., in a direction from the first major face  30  to the second major face  34 , and a specified overall length L s , e.g., in a direction along the axis  38  in  FIG. 3 , can include first selecting a specified overall width W s  for the metal stud  10  and a specified overall length L s  for the metal stud  10 . For example, the specified overall width W s  can be about 8 inches, about 6 inches, or about 3⅝ inches, and the specified overall length L s  can be about 8 feet, about 10 feet, or about 12 feet. The method can also include selecting a nominal pitch for the continuous wire matrix  208 , which can be about 6 inches, and the distance L, as shown in  FIG. 3 . 
     Once these dimensions have been selected or otherwise identified, a degree of stretching for the continuous wire matrix  208  can be determined. For example, it has been found to be advantageous to manufacture the metal stud  10  so that when the metal stud  10  is fabricated and singulated, such as by the flying shear cutting system  232 , apexes (e.g., apexes  22   a ,  22   b ,  24   a , and/or  24   b ) of the first and second angled continuous wires  18  and  22  are located at both ends of the metal stud  10  along its length and welded to respective ends of the first and second elongated channel members  12  and  14  along their lengths, as illustrated in  FIGS. 1A, 3, and 4 . 
     Thus, the degree of stretching can be determined so that, after the continuous wire matrix  208  has been stretched, a first pair of apexes of the zig-zag wires  204  (e.g., where the first pair of apexes are diametrically opposed to one another across a width of the zig-zag wires  204 ) is spaced apart from a second pair of apexes of the zig-zag wires  204  (e.g., where the second pair of apexes are diametrically opposed to one another across a width of the zig-zag wires  204 ) by the selected specified overall length L s  for the metal stud  10 . Thus, when the continuous elongate metal stud  228  is singulated by the flying shear cutting system  232 , the first pair of apexes is located at a first end of the singulated metal stud  10 , the second pair of apexes is located at a second end of the singulated metal stud  10  opposite to its first end, the first pair of apexes is welded to respective first ends of the singulated channel members  12  and  14 , and the second pair of apexes is welded to respective second ends of the singulated channel members  12  and  14  opposite to their first ends. 
     The method can then include determining a nominal width for the continuous wire matrix  208 , which can be configured to facilitate the assembly of the metal stud  10  to have the selected specified overall width W s . For example, the nominal width can be equal to the specified overall width W s , minus the combined thicknesses of the first and second major faces  30  and  34 , minus two times the selected distance L, plus an expected width difference, corresponding to the width difference W d , resulting from the stretching of the continuous wire matrix  208  by the determined degree of stretching. 
     The zig-zag wire benders  202  can then form the zig-zag wires  204  such that once they are welded to one another by the first welding system  206  to form the continuous wire matrix  208 , and before the continuous wire matrix  208  is stretched, the continuous wire matrix  208  has the selected nominal pitch and the determined nominal width. The first welding system  206  can then weld the zig-zag wires  204  to one another to form the continuous wire matrix  208 . The first and second conveyors  210 ,  226 , can then pull on the continuous wire matrix  208  in opposite directions to stretch the continuous wire matrix  208  by the determined degree of stretching, either elastically or plastically, and to pull the continuous wire matrix  208  through the assembly line  200 . The first conveyor  210  and the plurality of rollers  220  can then carry the stretched continuous wire matrix  208  from the first processing line  240  to the second processing line  242  and into physical proximity and/or engagement with the continuous elongated channel members  216 . 
     The second welding system  222  can then weld the continuous wire matrix  208  to the continuous elongated channel members  216 , and the flying shear cutting system  232  can cut the continuous elongate metal stud  228 , such as by cutting the continuous elongate metal stud  228  at locations where the apexes (e.g., the first and second pairs of the apexes) of the continuous wire matrix  208  are welded to the flanges of the continuous elongated channel members  216 , into individual or singulated metal studs such as metal stud  10 . Such singulated metal studs can have wire matrices that remains in tension after singulation and even after installation at a work site. Thus, the methods described herein can result in metal studs having wire matrices that carry residual stresses after fabrication. 
     By fabricating the continuous wire matrix  208  to have a nominal pitch of about 6 inches, and stretching the continuous wire matrix  208  to have a stretched pitch that is greater than the nominal pitch by a pitch difference of between 0 inches and at least ⅜ inch, the assembly line  200  and the features described herein can be used to fabricate the metal stud  10  to have apexes of its first and second angled continuous wires  18  and  20  welded to both ends of the first and second elongated channel members  12  and  14  while having any specified overall length L s  above 8 feet. 
     It has been found that the features described herein can be used to fabricate a metal stud having a variation in the pitch of its wire matrix along its length of within the range of ±0.062 inches, or in some cases within the range of ±0.010 inches, and having ends of the first and second angled continuous wires  18  and  20  coincide with apexes (e.g., apexes  22   a  and  24   b  or apexes  22   b  and  24   a ) of the first and second angled continuous wires  18  and  20  to within the range of 0.010 inches. Thus, the features described herein can be used to fabricate a metal stud having an accuracy of its length of within in the range of ±0.040 inches, within in the range of ±0.030 inches, or within in the range of ±0.020 inches. It has also been found that the features described herein can be used to fabricate a metal stud having a variation in the pitch of its wire matrix along its length (e.g., a difference between the largest individual pitch and the smallest individual pitch along the length of the stud) that is relatively large, such as at least 1%, at least 2%, at least 3%, at least 4%, or at least 5% of the average (e.g., mean) pitch of the wire matrix over the length of the stud. 
     A method of continuously fabricating a plurality of metal studs using the assembly line  200  can include receiving an order for a plurality of metal studs having a variety of specific lengths and a variety of specific widths, such as may be requested by a customer, and selecting the specified overall width W s  and the specified overall length L s  for each of the plurality of metal studs to match the dimensions requested by the customer. The method can also include continuously fabricating the two zig-zag wires  204 , continuously welding the zig-zag wires  204  to one another to continuously form the continuous wire matrix  208 , continuously stretching the continuous wire matrix  208 , continuously forming and introducing the continuous elongated channel members  216 , and continuously welding the continuous wire matrix  208  to the continuous elongated channel members  216 , to continuously form the continuous elongate metal stud  228 , in accordance with the features described above for forming an individual metal stud. 
     As the continuous elongate metal stud  228  travels through the flying shear cutting system  232 , the cutting system  232  can cut or singulate the continuous elongate metal stud  228  into a series of individual metal studs, such as a series of metal studs each having the specified overall length L s  and the specified overall width W s  for that respective metal stud. In some cases, the requested stud having the smallest specified degree of stretching can be the first stud to be formed and singulated, with studs of the same specified degree of stretching being formed and singulated immediately thereafter. Once the studs of the smallest specified degree of stretching have been formed, the assembly line  200  can be adjusted to fabricate the requested stud having the second smallest specified degree of stretching. Such an adjustment can be achieved by increasing the forces the first and second conveyors  210  and  226  exert on the continuous wire matrix  208  or by increasing the difference in the speeds at which the first and second processing lines  240  and  242  move the continuous wire matrix  208  through the assembly line  200 . Such an adjustment can result in the fabrication of a transition stud having a wire matrix with two different pitches, or with a variable pitch, which in some cases may be scrapped, while in other cases, may be useable as one of the requested studs, depending on the circumstances. 
     Once the assembly line  200  has been adjusted, all requested studs having the second smallest specified degree of stretching can be fabricated, and the process can be repeated for all of the requested studs. In other cases, the requested stud having the largest specified degree of stretching can be the first stud to be formed and singulated, with studs of deceasing specified degrees of stretching being formed and singulated thereafter, until all of the requested studs have been fabricated. Adjustments of the assembly line  200  can be achieved in such cases by decreasing the forces the first and second conveyors  210  and  226  exert on the continuous wire matrix  208  or by decreasing the difference in the speeds at which the first and second processing lines  240  and  242  move the continuous wire matrix  208  through the assembly line  200 . 
     In some cases, the requested stud having the smallest specified overall length L s  and/or the smallest specified overall width W s  can be the first stud to be formed and singulated, with studs of the same specified overall length L s  and/or the same specified overall width W s  being formed and singulated immediately thereafter. The assembly line  200  can then be adjusted to fabricate the requested stud having the second smallest specified overall length L s  and/or the second smallest specified overall width W s , such as by adjusting the operation of the first and second conveyors  210 ,  226  to adjust the assembly line  200  to fabricate a stud having a larger specified overall length L s , by adjusting the operation of the flying shear cutting system  232  to cut studs having a larger specified overall length L s , and/or by adjusting the zig-zag wire benders  202  to adjust the assembly line  200  to fabricate a stud having a larger specified overall width W. The process can be repeated for all of the requested studs. In other cases, the requested stud having the largest specified overall length L s , and/or the largest specified overall width W s  can be the first stud to be formed and singulated, with studs of deceasing dimensions being formed and singulated thereafter, until all of the requested studs have been fabricated. 
     As described above, the features described herein can be used to fabricate the metal stud  10  to have apexes of its first and second angled continuous wires  18  and  20  welded to both ends of the first and second elongated channel members  12  and  14  while having any specified overall length L s  above 8 feet. Such results provide important advantages. For example, by manufacturing metal studs to specific lengths in a factory setting, the need to cut or trim studs to length during installation can be reduced or eliminated, improving installation efficiency. 
     Further, fabricating metal studs such as metal stud  10  to have apexes of its first and second angled continuous wires  18  and  20  welded to both ends of the first and second elongated channel members  12  and  14  makes the metal stud  10  symmetrical, so that installers can install the stud  10  without regard to which end of the stud is the top or the bottom end of the stud  10 , eliminates the sharp ends of the wires  18  and  20  that would otherwise pose hazards during installation, and increases web crippling strengths of the stud  10  at its respective ends. Further, fabricating metal studs such as metal stud  10  to have apexes of its first and second angled continuous wires  18  and  20  welded to both ends of the first and second elongated channel members  12  and  14  facilitates installation of a series of metal studs so that the passages  28  are aligned, or at least more closely aligned, across the series of metal studs. 
       FIGS. 7-11  show a reinforcement plate  600  for use with the metal stud to fabricate a metal framing member  1100  ( FIGS. 12-16 ), according to at least one illustrated embodiment. In particular,  FIG. 11  shows the reinforcement plate  600  in a flattened or unfolded configuration, while  FIGS. 7-10  show the reinforcement plate  600  in a folded configuration. 
     The reinforcement plate  600  may have a rectangular profile, having a length L p  and a width W p , and having a gauge or thickness of material G that is generally perpendicular to the profile and hence the length L p  and the width W. The reinforcement plate  600  has a first pair of opposed edges  602   a ,  602   b , a second edge  602   b  of the first pair opposed to a first edge  602   a  of the first pair across the length L p  of the reinforcement plate  600 . The reinforcement plate  600  has a second pair of opposed edges  604   a ,  604   b , a second edge  604   b  of the second pair opposed to a first edge  604   a  of the second pair across the width W p  of the reinforcement plate  600 . 
     Between the first and the second pair of opposed edges  602   a ,  602   b ,  604   a ,  604   b  is a center or plate portion  606  of the reinforcement plate  600 . The center or plate portion  606  of the reinforcement plate  600  is preferably corrugated, having a plurality of ridges  608   a  and valleys  608   b  (only one of each called out for clarity of illustration), the ridges  608   a  and valleys  608   b  which extend between the first and the second edges  602   a ,  602   b  of the first pair of opposed edges, that is across the length L p  of the reinforcement plate  600 . The ridges  608   a  and valleys  608   b  preferably repeat in a direction along which the first and the second edges  602   a ,  602   b  extend, that is repeating along the width W p  of the reinforcement plate  600 . The corrugations provide structural rigidity to the reinforcement plate  600 . The pattern may be continuous, or as illustrated may be discontinuous, for example omitting ridges  608   a  and valleys  608   b  in sections between pairs of opposed tabs (e.g., opposed pair of tabs  610   a ,  612   a , and opposed pair of tabs  610   b ,  612   b ). 
     While first and second edges  602   a ,  602   b  are illustrated as straight edges that extend in a straight line between opposed edges  604   a ,  604   b , the first and second edges  602   a ,  602   b  can advantageously be notched or serrated to minimize contact between the first and second edges  602   a ,  602   b  and the elongated channel members  12 ,  14 , with contact limited to only a few portions that are fastened or secured directly to the channel members  12 ,  14 , thereby reducing heat transfer. 
     The reinforcement plate  600  has at least one upstanding portion  610   a - 610   b  along the first edge  602   a  and at least one upstanding portion  612   a - 612   b  along the second edge  602   b . The upstanding portions  610   a ,  610   b  may take the form of a respective pair of tabs that extend perpendicularly from the plate portion  606  along the first edge  602   a  and a respective pair of tabs that extend perpendicularly from the plate portion  606  along the second edge  602   b.    
     As illustrated in  FIGS. 12-16 , the reinforcement plate  600  can be physically secured to the metal stud  10  via the at least one upstanding portion  610   a ,  610   b  along the first edge  602   a  and the at least one upstanding portion  612   a ,  612   b  along the second edge  602   b . For example, the reinforcement plate  600  can be welded by welds to the metal stud  10  via the tabs  610   a ,  610   b ,  612   a ,  612   b  that extend perpendicularly from the plate portion  606 . For instance, a first set of welds can physically secure the respective pair of tabs  610   a ,  610   b  that extend perpendicularly from the plate portion  606  along the first edge  602   a  to the first flange  32  of the first elongated channel member  12 , and a second set of welds can physically secure the respective pair of tabs  612   a ,  612   b  that extend perpendicularly from the plate portion  606  along the second edge  602   b  to the first flange  36  of the second elongated channel member  14 . 
     The reinforcement plate  600  can be physically secured to the metal stud  10  so that the edges  602   a ,  602   b  of the reinforcement plate  600  are within and enclosed by the first and second elongated channels  12  and  14 . For example, the first edge  602   a  can be positioned adjacent the major face  30  and between the flanges  32  and  42 , and the second edge  602   b  can be positioned adjacent the major face  34  and between the flanges  36  and  44 . In such an embodiment, the reinforcement plate  600  can be adjacent to, abutting, and in contact with the wire matrix  16 , and can be within or on the inside of the metal stud  10 . 
     In various embodiments, the reinforcement plate  600  can be physically secured, connected, fixed, or coupled to the other components of the metal stud  10  using any suitable mechanisms, methods, fasteners, or adhesives. For example, the reinforcement plate  600  can be physically secured to the other components of the metal stud  10  by an interference fit between the first and second elongated channel members  12 ,  14 , such as between their respective major faces  30  and  34 . In such an example, the length L p  of the reinforcement plate  600  can be slightly larger than a distance between the major faces  30  and  34 , so that the reinforcement plate  600  is secured by an interference fit between the major faces  30 ,  34  when positioned between them. 
     As another example, the reinforcement plate  600  can be resistance welded to the other components of the metal stud  10 . In such an example, the tabs  610   a ,  610   b ,  612   a , and  612   b  of the reinforcement plate  600  can be resistance welded to the major faces  30  and  34 , or the center or plate portion  606  of the reinforcement plate  600  can be resistance welded to the flanges  32  and  36  or to the wire matrix  16 . As yet another example, the reinforcement plate  600  can be secured to the other components of the metal stud  10  by swaging or radially cold expanding a bushing or bushing assembly via passage of a tapered mandrel, where the bushing extends through aligned apertures or openings formed in the major faces  30  and  34  and the tabs  610   a ,  610   b ,  612   a , and  612   b . For example,  FIG. 17  illustrates a bushing assembly  702  that extends through aligned apertures in the tab  610   a  and the major face  30 , and that has been swaged or radially cold expanded to secure the tab  610   a  to the major face  30 . As yet another example, the reinforcement plate  600  can be secured to the other components of the metal stud  10  by rivets extending through aligned apertures or openings formed in the major faces  30  and  34  and the tabs  610   a ,  610   b ,  612   a , and  612   b . For example,  FIG. 18  illustrates a rivet  708  that extends through aligned apertures in the tab  610   a  and the major face  30 , and that has been used to secure the tab  610   a  to the major face  30 . 
     As another example, the reinforcement plate  600  can be physically secured to the other components of the metal stud  10  by clinching or press joining the reinforcement plate  600  to the first and second elongated channel members  12  and  14 . In such an example, the tabs  610   a ,  610   b ,  612   a , and  612   b  of the reinforcement plate  600  can be clinched to the major faces  30  and  34  of the elongated channel members  12  and  14 , or the center or plate portion  606  of the reinforcement plate  600  can be clinched to the flanges  32  and  36  of the elongated channel members  12  and  14 . For example,  FIG. 19A  illustrates the tab  610   a  being positioned adjacent to the major face  30  in preparation for a clinching operation, and  FIG. 19B  illustrates the tab  610   a  clinched to the major face  30  after the clinching operation is complete. The clinching operation can use a punch to press and deform the tab  610   a  and major face  30  at a location indicated by reference numeral  704  to form an interlocking structure indicated by reference numeral  706  to lock the tab  610   a  to the major face  30 . Additional information regarding clinching operations can be found in U.S. Pat. Nos. 8,650,730, 7,694,399, 7,003,861, 6,785,959, 6,115,898, and 5,984,563, and U.S. Pub. Nos. 2015/0266080 and 2012/0117773, all of which are assigned to BTM Corporation. 
     A first reinforcement plate  600  may be fixed at least proximate or even at a first end of the metal stud  10 , and a second reinforcement plate  600  may be fixed at least proximate or even at a second end of the same metal stud  10 . The first and second reinforcement plates  600  can be coupled to the other components of the metal stud  10  by any of the mechanisms, methods, fasteners, or adhesives described herein. The first and second reinforcement plates  600  can be coupled to the other components of the metal stud  10  by the same or by different mechanisms, methods, fasteners, or adhesives. 
     Patent Cooperation Treaty application number PCT/CA2016/050900, published as international publication number WO 2017/015766, and U.S. Provisional Patent Application No. 62/545,366, are hereby incorporated herein by reference, in their entirety. 
     Those of skill in the art will recognize that many of the methods set out herein may employ additional acts, may omit some acts, and/or may execute acts in a different order than specified. 
     The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.