Manufacturing Capabilities for Custom Metal Springs
From prototype validation to stable mass production — engineered control over every forming, heat treatment, and inspection step.
Send Drawing for Capability Check
What We Actually Manufacture
Structural forms we control from coiling to final inspection — not applications, just manufacturing boundaries.
Compression Springs
Wire diameter 0.2mm–8mm, coil pitch control within ±0.05mm, stress-relieved for consistent load characteristics across production runs.
Extension Springs
Controlled hook/loop forming geometry, initial tension verification per spring, heat treatment prevents hook breakage under cyclic loads.
Torsion Springs
Leg angle tolerance ±2°, torque testing at specified deflection angles, body winding consistency maintains predictable spring behavior.
Flat Spiral / Constant Force Springs
Thickness variation <0.02mm across width, pre-stress control for uniform force output, edge finishing prevents premature fatigue cracking.
Wire Forms
Multi-axis CNC bending for complex geometries, bend radius verification prevents material cracking, dimensional consistency within ±0.1mm.
Custom Bent Wire Components
Drawing-to-forming process validation, spring-back compensation based on material properties, fixture-based quality control for repeatability.
Battery Contact Springs
Contact force testing per piece, plating thickness measurement for conductivity assurance, dimensional stability under thermal cycling verified.
Retaining Clips & Fasteners
Retention force verification, edge deburring for assembly safety, material hardness testing ensures specified grip strength in application.
Need a structure not listed? We'll evaluate manufacturability before quoting.
Submit Your Design SpecificationsManufacturing Process Flow
Engineering-reviewed workflow, not sales-driven promises — process locked before volume production begins.
Drawing Review & Risk Check
Engineers assess tolerance feasibility, material suitability, and identify potential forming challenges before accepting the project.
Material Confirmation
Verify material certificates, test hardness and tensile properties, confirm traceability documentation meets specification requirements.
Tooling & Setup
CNC programming for coiling parameters, fixture preparation for forming operations, first-piece inspection calibration before production.
Prototyping & Sampling
Dimensional verification against drawing, functional load testing, heat treatment validation, surface finish inspection per specification.
Process Lock for Mass Production
Document approved parameters, lock machine settings, establish inspection frequency, freeze process until engineering approval for any changes.
In-Process Inspection
Continuous dimensional monitoring, load testing at defined intervals, surface quality checks, immediate correction when deviation detected.
Final Inspection & Packing
100% visual inspection, random sampling for functional testing, protective packaging to prevent transit damage, traceability labels applied.
Documentation & Shipment
Material certificates, inspection reports, dimensional data sheets included with shipment, full traceability to batch and production date.
Manufacturing Control Principles
Engineering-reviewed, not sales-decided — technical feasibility confirmed before quotation.
Process locked before volume production — no parameter changes without engineering approval.
Traceability maintained throughout — from raw material receipt to final shipment documentation.
Experience manufacturing transparency from drawing review to delivery.
Request Process DocumentationMaterial Capability
Controlled material sourcing with certificates and traceability — we specify what we can deliver, not vague promises.
Carbon Steel
Stainless Steel
Alloy Steel
Special Materials
Material Documentation & Traceability
Confirm material availability and certification requirements for your project.
Discuss Material SpecificationsForming & Coiling Capability
Controlled manufacturing dimensions, not equipment marketing — we specify achievable structures and precision ranges.
CNC Spring Coiling
Computer-controlled coiling maintains consistent pitch, diameter, and total coil count across production runs — eliminates manual operator variation.
Multi-Axis Wire Forming
3D bending for complex leg configurations, hook angles, and custom end forms — programming verified against drawing before production start.
Tight Tolerance Control
Free length ±0.5mm typical, outside diameter ±0.1mm achievable on critical dimensions — capability confirmed during prototype sampling.
Complex Leg & Hook Forming
Custom end configurations with controlled bend radii to prevent stress concentrations — hook strength verified through tensile testing.
Manufacturing Dimension Ranges
Verify if your design falls within our controlled manufacturing ranges.
Check Design FeasibilityHeat Treatment & Stress Relief
Controlled thermal processing for spring performance consistency — not optional for applications requiring cycle life.
Stress Relief Purpose
Removes residual stresses induced during coiling and forming operations, prevents dimensional drift during service, stabilizes spring properties for consistent performance over time.
Spring Performance Consistency
Heat treatment ensures spring rate remains within ±5% across production batches, eliminates settling behavior in cyclic loading applications, maintains dimensional stability under temperature variations.
Not Optional for Critical Springs
Springs subjected to cyclic loading require stress relief to prevent premature fatigue failure, applications with tight load tolerances depend on heat treatment for specification compliance, we recommend heat treatment based on application requirements, not cost reduction.
Heat Treatment Benefits for Spring Reliability
Extends fatigue life by 3-5x in cyclic loading applications
Prevents load rate drift during extended service periods
Enables tighter load tolerance compliance in production
Determine if your application requires heat treatment for reliable spring performance.
Consult on Heat Treatment NeedsSurface Treatment & Finishing
Controlled coating processes with dimension impact disclosure — critical parts require pre-confirmation, not assumptions.
| Treatment Type | Corrosion Protection | Typical Thickness | Dimensional Impact |
|---|---|---|---|
| Zinc Plating | Moderate indoor protection, salt spray resistance 96-120 hours | 5-15 microns | +0.01-0.03mm per surface |
| Black Oxide | Minimal corrosion resistance, cosmetic finish only | <1 micron | Negligible dimension change |
| Powder Coating | Excellent outdoor protection, chemical resistance | 50-100 microns | +0.10-0.20mm per surface |
| Passivation (Stainless) | Enhanced corrosion resistance for stainless steel | Molecular level | No dimensional change |
| Electropolishing | Superior corrosion resistance, removes surface contaminants | Removes 5-25 microns | -0.01-0.05mm reduction |
Critical Dimension Notification
Surface treatments add or remove material, affecting final dimensions. For springs with tight diameter, length, or load tolerances, surface finish must be confirmed during drawing review. Post-plating dimensional verification is standard for critical applications. We do not apply coatings blindly to tight-tolerance parts without engineering approval.
Confirm surface treatment compatibility with your dimensional requirements.
Discuss Finishing SpecificationsTolerance & Consistency Control
Understanding tolerance as a manufacturing reality, not a negotiation — we control variation within stated limits across batches.
How We Understand Tolerance
Tolerance defines acceptable variation range, not a target. Dimensions cluster within this range due to process capability. Tighter tolerances require additional process controls and increase manufacturing cost.
Which Dimensions Lose Control Easily
Free length varies with coil count consistency. Outside diameter affected by wire tension during coiling. Load rate depends on material hardness uniformity and heat treatment effectiveness.
How We Maintain Batch Consistency
Process parameters locked after sample approval. In-process measurement at defined intervals. Statistical process control identifies drift before parts fall outside tolerance.
Critical Dimensions Most Prone to Variation
Affected by coil count precision, end grinding uniformity, and material springback after coiling.
Influenced by material hardness variation, heat treatment consistency, and wire diameter tolerance.
Controlled by coiling mandrel accuracy, wire tension settings, and springback compensation.
Verify if your tolerance requirements align with our process capabilities.
Review Tolerance FeasibilityPrototyping & Sampling Capability
Sample-to-production consistency verified before mass manufacturing — prototypes prove process capability, not just part feasibility.
Sample Development to Production Lock
Sample Purpose
Validate design manufacturability, confirm material performance, establish baseline for production quality standards.
Verification at Sample Stage
Complete dimensional inspection, functional load testing, material certificate verification, surface finish approval.
Sample → Production Consistency
Exact process parameters documented, tooling locked for replication, first production run verified against approved sample.
What Gets Verified During Sampling
Dimensional compliance against drawing specifications
Load testing at specified deflection points
Material certificate matching specification requirements
Surface finish quality and coating thickness
Heat treatment verification through hardness testing
Process parameter documentation for production replication
Start with a sample to validate manufacturability before committing to volume production.
Request Sample DevelopmentProduction Scale & Batch Logic
Volume capability without capacity claims — batch size scaled after process validation, not determined by machine availability.
Small Batch
Limited production runs for design validation, market testing, or initial deployment before full-scale commitment.
Pilot Run
Mid-volume production to verify process stability before long-term programs, confirms consistency across multiple production cycles.
Long-term Programs
Ongoing production with locked processes, dedicated tooling, and established quality baselines for consistent delivery over extended periods.
Production Scaling Principles
Batch volume is not randomly scaled — process validated at sample stage before quantity increase.
Quality standards do not degrade with volume — same inspection criteria apply to first piece and last piece.
Process locked after approval, quantity expansion only after demonstrating stable production across multiple batches.
Discuss appropriate batch size and scaling plan for your production requirements.
Plan Your Production VolumeHave a drawing or specification?
Our engineers review manufacturability before quotation. Get technical feasibility assessment, material recommendations, and realistic lead time — not just a price.
Submit Drawing for Capability ReviewEngineering-reviewed within 24-48 hours | No obligation for feasibility assessment