Phillip,
I only need one size of tap & die, which is for 0.8mm wire. For me I think a range from 0.5mm to 1mm would be useful if I get the time to use them in a design.
J.I. Morris Company might have what you are looking for. It would
also appear from your description that you want to cut non-standard
thread pitch for advancing the screw further with less number of
turns. They have services for custom work also.
http://www.morris01550.com/products.htm
If I were looking at such a process, then I would probably try
serrated plates held in parallel, with just enough space between the
plates to roll the thread onto the wire.
HTH,
Jeff Simkins