Brian, It just so happens I got a flyer from Small Parts, Inc.
yesterday which now has them selling the best size varieties of
6Al-4V titanium wire I have ever found (.005"-.25"). This alloy is
substantially stronger than commercially pure Ti, and I’ll bet will
solve your problems. They sell lots of small things in small
quantities (their name mandates it). http://www.smallparts.com
Incidentally, I really love the work you do.