Prototyping & Sampling for Custom Springs
Validate fit, function, and performance before production. Our samples follow production processes—not temporary shortcuts—so you can trust what you test is what you'll get.
Understanding Your Options: Prototype vs. Sample vs. Pilot
Different stages require different approaches. We clarify what each option delivers so you choose the right path for your timeline and validation needs.
Verify design, fit, and basic function quickly
- Dimensional and assembly validation
- May use expedited processes for speed
- Ideal for design iteration phase
- Functional testing of core parameters
- Fastest turnaround option
Production-representative parts for qualification
- Same materials as production runs
- Full process sequence matched to volume orders
- Consistent inspection methods applied
- Performance testing under real conditions
- Batch traceability documentation
Production line validation and process verification
- Production cycle time verification
- Consistency across batch confirmed
- Packaging and labeling tested
- Quality control plan execution
- PPAP/FAI support available
Not sure which option fits your project timeline?
Tell Us Your GoalOur 4-Step Prototyping Workflow
From drawing upload to finished samples, every step is designed to reduce risk, catch issues early, and deliver parts you can trust.
Input Review
We examine what you need
- Drawing or sample analysis
- Target force/torque values
- Operating conditions review
- Life cycle requirements
- Assembly constraints check
DFM & Risk Flags
We identify potential issues
- Material availability confirmation
- Wire diameter forming limits
- Heat treatment feasibility
- Coating compatibility check
- Alternative recommendations
Prototype Build
Manufacturing execution
- CNC coiling to spec
- Heat treatment cycle
- Surface finishing process
- Stress relief operations
- Final dimensional adjustment
Inspection & Delivery
Quality verification
- Dimensional measurement
- Load/torque testing
- Visual inspection
- Packaging with traceability
- Delivery with documentation
Ready to see this process in action for your project?
Start Your PrototypeWhat We Need From You
The more complete your input, the faster and more accurate your quote. Here's what helps us serve you best in each scenario.
- 2D/3D file (PDF, STEP, IGES)
- Wire diameter specified
- OD or ID dimension
- Free length noted
- Total coils or active coils
- End configuration details
- Target load @ height (compression)
- Target torque @ angle (torsion)
- Operating stroke range
- Expected cycle life
- Physical sample shipped to us
- Application description
- Environment conditions
- Failure mode observed (if any)
- Performance expectations
- Material preference (if known)
- Surface finish requirements
- Tolerance criticality notes
- Installation method
- Desired improvement areas
- Space constraints (max OD/ID/length)
- Required force or torque output
- Travel distance needed
- Mounting method description
- Operating temperature range
- Corrosion exposure level
- Number of cycles expected
- Assembly direction/orientation
- Similar reference springs (if any)
- Industry/application context
- Annual volume range (helps us recommend prototype vs. sample run)
- Target delivery date (standard or expedited)
- Primary contact for technical questions
Have questions about what information you need to provide?
Contact Our Engineering TeamLead Time Expectations & Expedite Conditions
We believe in honest timelines. Here's what affects delivery speed and when we can fast-track your samples.
- Material in stock
- Standard wire diameters
- Common end configurations
- No special coatings required
- Simple geometry
- Low production queue
- Custom specifications
- Material procurement needed
- Heat treatment cycles
- Surface finishing steps
- Complex end forms
- Full inspection protocol
- Process stabilization time
- Batch quantity production
- Quality plan preparation
- Documentation assembly
- Material certification
- Traceability setup
Factors that extend lead time: Unusual materials, multiple coating layers, complex multi-axis wire forms, high-temperature requirements, non-standard tolerances, and current production capacity. We'll always tell you upfront what timeline is realistic for your specific project.
Need your samples faster than our standard turnaround?
Discuss Expedite OptionsWhy Our Samples Represent Production
Many suppliers rush samples with shortcuts that don't match production reality. We ensure sample runs use the same logic, processes, and standards as your volume orders.
Same Material Logic
Samples use the exact material grade you'll receive in production. We can even match specific batch sourcing strategies for critical applications.
- Music wire grade selection matched
- Stainless alloy specifications locked
- Supplier consistency maintained
Same Critical Process
Key manufacturing steps—coiling parameters, heat treatment profiles, stress relief cycles—mirror your production path exactly.
- Identical forming equipment settings
- Heat treatment temperature/time matching
- Surface treatment method consistency
Same Inspection Plan
Measurement methods, test equipment, and acceptance criteria for samples directly transfer to production quality control.
- Dimensional gauging consistency
- Load/torque test protocols aligned
- Visual inspection standards unified
Confident your samples will match production performance?
Request Sample RunWhat You Receive: More Than Just Springs
Professional prototyping includes complete documentation, test data, and traceability—not just parts in a bag.
Sample List
Complete inventory showing quantity, revision number, lot code, and manufacturing date for every piece delivered.
Dimensional Report
Measured values for critical dimensions—wire diameter, OD/ID, free length, coil count—with tolerances and conformance status.
Load/Torque Check
Functional test results showing actual force-deflection or torque-angle performance against your target specifications.
Material & Finish Notes
Documentation of material grade, heat treatment applied, surface coating type, and any special processing performed.
Revision Tracking
Change log noting any design modifications made during prototyping and how they differ from initial specifications.
Packaging Details
Professional labeling with part numbers, quantities, and protective packaging to prevent damage during shipping and storage.
FAI (First Article Inspection)
Complete dimensional and functional verification per AS9102 standards for aerospace and defense applications requiring formal documentation.
PPAP Package
Full Production Part Approval Process documentation for automotive tier suppliers, including control plans and capability studies.
Need specific documentation for your industry standards?
Discuss RequirementsTesting Capabilities for Prototypes
We verify more than just "looks right." Every sample undergoes measurement and functional testing to confirm it meets your design intent.
Dimensional Verification
Free length, outer/inner diameter, leg geometry, wire diameter, coil count, end angle positioning
Functional Performance
Load @ height (compression), initial tension (extension), torque @ angle (torsion), rate verification across working range
Set & Relaxation Check
Permanent deformation assessment, stress relaxation tendency evaluation based on application requirements
Visual & Surface Quality
Coating uniformity, burr inspection, crack detection, surface finish verification, corrosion resistance spot checks
Want to understand our full testing protocol for your specific spring type?
Request Test Plan DetailsCommon Prototype Issues & How We Prevent Them
Years of experience have taught us where springs fail. We flag these risks during engineering review and adjust design or process to avoid disappointment.
Unstable Force Output
- Material batch variation
- Incomplete heat treatment cycle
- Inconsistent coil count
- Insufficient stress relief
- Material certification verification
- Standardized heat treatment profiles
- Automated coil counting
- Post-forming stress relief steps
Premature Breakage
- Stress concentration at bends
- Sharp end transitions
- Surface defects or scratches
- Improper tempering temperature
- Controlled bend radius design
- Smooth end forming techniques
- Surface inspection protocols
- Temperature-monitored tempering
Assembly Fit Problems
- OD/ID tolerance stack-up
- End angle misalignment
- Free length variation
- Insufficient assembly clearance
- DFM assembly review upfront
- Tighter dimensional controls
- End positioning verification
- Tolerance analysis consultation
Worried about a specific failure mode in your application?
Get Engineering Consultation
Professional Packaging & Labeling
Even prototypes deserve engineered packaging. We treat every sample shipment with the same care as production orders.
Traceability Labels
Every bag includes Part Number, Revision, Quantity, Lot Code, and Manufacturing Date—so you always know exactly what you're testing.
Protection by Material
Carbon steel gets VCI (vapor corrosion inhibitor) packaging. Stainless and coated springs receive anti-scratch separators. Custom foam inserts for delicate wire forms.
International Shipping Ready
Export cartons with proper shipping marks, commercial invoice, packing list, and certificate of origin (when required). Compliant with customs documentation needs.
Need specific packaging for regulated industries or special handling?
Discuss Custom PackagingYour Designs Stay Confidential
Secure file handling with encrypted transfer
NDA available upon request
Drawings used only for quoting & manufacturing
Frequently Asked Questions
Quick answers to the most common questions about our prototyping and sampling services.
When should I choose Prototype vs. Sample Run vs. Pilot?
Choose Prototype for fast design validation and fit checks. Choose Sample Run when you need production-representative parts for qualification testing. Choose Pilot Run when you're ready to verify manufacturing consistency and prepare for volume production with PPAP/FAI documentation.
What's the minimum prototype quantity? Can I order just 1 piece?
Yes, we can produce single prototypes for initial design validation. However, for statistically meaningful testing or production qualification, we recommend at least 5-10 pieces to assess process consistency and part-to-part variation.
What qualifies for expedited/fast-track prototyping?
Fast-track delivery (3-5 days) is available when we have your specified material in stock, the design uses standard wire diameters and common end configurations, no special coatings are required, and our production queue has capacity. We'll confirm eligibility when reviewing your quote request.
Do prototypes use the same final production materials?
Yes, for Sample Runs we always use the exact material grade specified for production. For quick Prototypes, we typically use production-equivalent material, but can expedite with similar-spec alternatives if time is critical—we'll always inform you of any substitutions upfront.
Can surface treatments be included in prototyping?
Absolutely. We can apply zinc plating, powder coating, e-coating, passivation, or other finishes to prototypes. Surface treatment typically adds 2-3 days to lead time depending on the specific process and batch scheduling.
If my prototype passes, will production parts be identical?
When you order a Sample Run (not a quick Prototype), production parts will match because we use the same materials, processes, and inspection methods. We lock the revision and maintain process consistency. Quick Prototypes may have minor process differences—we recommend Sample Runs for final qualification.
What test data and reports do you provide with samples?
Standard deliverables include dimensional measurements, load/torque test results, material certifications, and visual inspection notes. Optional add-ons include FAI reports (AS9102), PPAP packages (AIAG), full material traceability, and custom test protocols per your specifications.
How do international customers receive samples?
We handle complete door-to-door logistics: export documentation, freight forwarding, customs clearance, and final delivery to your facility. You receive one tracking number and one point of contact. Express shipping (DHL/FedEx) typically takes 3-5 days internationally.
Do you support complex assemblies, hooks, or multi-axis wire forms?
Yes, we prototype extension springs with custom hooks, torsion springs with complex leg geometries, and intricate wire forms with multiple bends. CNC equipment allows precise control of 3D shapes. Share your design and we'll confirm feasibility.
If the prototype doesn't meet specs, how does iteration work?
We review test data together to identify the root cause—whether design, material, or process related. Minor adjustments (within tolerance band) are typically no-charge. Significant design changes require a new quote. We work collaboratively to reach your performance target efficiently.
Have a question not covered here?
Ask Our Technical TeamRequest Your Prototype Quote
Fill out the form below and our engineering team will respond within 24-48 hours with pricing, lead time, and technical feedback.