Avoiding Errors During the Spring Manufacturing Process, Part 1

At Custom Spring Manufacturing, we’re proud to serve as your experts when it comes to custom spring engineering of a variety of spring types, from torsion springs and compression springs to many other formats. We offer design, engineering and fabrication for all of our spring types, bringing quality springs to customers in a variety of major industries.

Unfortunately, our decades of experience in the spring manufacturing world has also exposed us to many of the mistakes that can be made by other spring manufacturers who do not have the proper expertise. This can include DIYers who attempt to manufacture springs on their own without the proper training, and it sadly sometimes also includes actual spring manufacturing companies. To ensure you never run into this sort of thing, this two-part blog series will go over a few of the most common mistakes made during the spring manufacturing process, plus how they can be avoided by both clients and manufacturers of new springs.

avoiding errors spring manufacturing

Bend Radius Concerns

One of the single most common issues found in modern spring manufacturing is too tight a bend radius, which refers to how close a spring’s bend comes to its edge. When the bend is too close to the edge, materials on either side of the bend can tear, leading to major issues with spring integrity.

In addition, down related lines, spring design must factor in the material type, tooling and bending method. This is to make sure springback, a natural reaction of a spring as it attempts to return to its natural shape, is properly predicted and accounted for during the spring’s working processes. When the bend radius is extremely thick, springback can be difficult to account for and may result in tears on the bend. However, proper manufacturing involves compensating for this by offsetting the edge with extra material, or by adding more material thickness to even out the radio between it and the bend radius.

End Type Selection

Another common error, one that can be made by both clients and manufacturers alike, is choosing the wrong end type for a given spring. End types play a big role in a spring’s performance, along with its index, coil number and stress tolerance. Some of the common end types available include:

  • Torsion spring ends: Those that resist rotary motion of components, usually with a straight piece of wire called a “leg.”
  • Compression spring end: This is the most common spring type, one that leaves space between the final two coils to resist shock or force. Ends may be closed and ground, closed and squared, double closed or even left open.
  • Extension spring end: These options start out in a compressed state, then are pulled apart. Their ends generally a hook or hoop format to allow this to happen.

Knowing which end type to choose requires expertise and understanding of the purpose the spring will be used for, so it’s vital to consult our experienced professionals when making this call.

For more on avoiding common errors made during the spring manufacturing process, or to learn about any of our custom springs, speak to the staff at Custom Spring Manufacturing today.