The characteristics of particles in the shot peening (SP) process play a critical role in enhancing the fatigue life and durability of automotive springs by inducing compressive residual stresses and surface hardening. The cut-wire (CW) method, an environmentally friendly manufacturing approach, produces shot particles with superior hardness and longer lifespans compared to conventional steel casting techniques. This study developed an analytical model based on the temporal synchronization of cutting and feed motions to investigate the effects of wire diameter, number of cutting edges, and feed rate on shot geometry, production rate, and power consumption. Experimental results from Iranian and Chinese machines demonstrated a 7.8% to 9.4% alignment accuracy with the analytical model. The production rate exhibited a quadratic relationship with wire diameter, reaching up to 85.67 kg/h with a 1.1 mm wire, while power consumption scaled with the cube of the diameter and linearly with the material’s ultimate tensile strength. Due to the device’s power limitation (5.5 kW), simultaneous multi-wire cutting was restricted for high-strength, large-diameter wires. These findings highlight the importance of optimizing process parameters to balance production efficiency and energy consumption. The study provides practical guidance for designing shot production machinery and improving shot peening processes in the automotive industry. Future research should focus on automation and further reducing environmental impacts.