We produce custom springs and wireforms. We do not stock standard parts.
We produce custom springs and wireforms. We do not stock standard parts.
Ace Wire Spring & Form Co., Inc. manufactures custom extension springs to customer specifications for OEMs, engineers, and industrial manufacturers. Extension springs are close wound helical springs designed to absorb and store energy while resisting a pulling force. Unlike standard catalog springs, custom extension springs are manufactured around the customer’s drawing, sample, dimensions, material requirements, load requirements, end configurations, tolerances, finish requirements, and application needs.
Ace supports custom extension spring projects from prototype and sample production through repeat production orders. Our team can provide design assistance, manufacturing feedback, and production suggestions based on decades of experience, while final design responsibility remains with the customer.
Extension springs are used when a product or assembly requires resistance to a pulling force, controlled tension, return force, load support, or movement control. They are commonly used in industrial equipment, doors, garage doors, appliances, agricultural equipment, lawncare equipment, valves, actuators, firearms, tensioning devices, material handling equipment, and OEM assemblies.
The performance of an extension spring depends on the application requirements. Important factors may include outside diameter, inside diameter, body length, overall length, wire size, material, end type, hook or loop configuration, initial tension, spring rate, load at length, maximum extension, operating environment, cycle life, and tolerance requirements.
Ace provides extension spring design assistance as part of qualified custom manufacturing opportunities. Customers may come to Ace with a complete drawing, a sample, a failed part, a photo, an incomplete print, or an application problem. Our team can review the available information and help identify what details may affect manufacturability, repeatability, material selection, load performance, initial tension, end configuration, tolerances, and production efficiency.
Extension spring performance can be heavily affected by hook style, loop geometry, bend radius, stress at the ends, available space, required extension, material choice, finish requirements, and environmental exposure. Discussing these details early can help reduce production issues, improve repeatability, and support a more accurate quote.
Ace can support prototype extension springs, sample production, and repeat production orders. Prototype and sample extension springs help customers evaluate fit, pull force, extension, hook configuration, assembly clearance, end performance, and manufacturability before moving into larger production quantities.
For production orders, Ace supports customers that need consistent repeatability, domestic manufacturing, scheduled releases, quantity break pricing, and blanket order programs. This makes Ace a strong fit for customers that need custom extension springs manufactured to specification over time, not one-time retail replacement parts.
Ace manufactures custom extension springs using spring materials selected around the application requirements, including strength, flexibility, corrosion resistance, forming needs, environmental exposure, fatigue life, and production demands. Extension springs may require specific materials, finishes, or secondary services depending on where and how the spring will be used.
Secondary services and finishes may include heat treating, stress relieving, deburring, painting, plating, passivation, and other finishing operations depending on the part requirements. Customers should include required finishes, coating specifications, material requirements, load requirements, and quality documentation needs when requesting a quote.
Ace is a strong fit for engineers, OEMs, purchasing teams, and industrial buyers that need custom extension springs manufactured to specifications. Ace is especially well suited for projects involving drawings, samples, prototypes, repeat production, tight tolerance requirements, load requirements, custom end configurations, domestic manufacturing, quality documentation, secondary services, blanket order planning, or ITAR registered supplier needs.
Ace may not be the right fit for customers looking for standard catalog extension springs, retail replacement springs, one-piece hobby orders, or immediate off-the-shelf inventory. Ace is a custom manufacturer, not a stock spring distributor.
To request a quote for a custom extension spring, send the available drawing, sample, photo, dimensions, material requirements, load requirements, end configuration, tolerances, finish requirements, application details, quality requirements, quantities, and expected production needs. If the project is still early stage, Ace can review the available information and help identify what may be needed to quote, prototype, or manufacture the spring.
For more detailed guidance, visit the Request a Quote Tips page.
What are custom extension springs?
Custom extension springs are close wound helical springs manufactured to customer specifications to resist a pulling force, store mechanical energy, and provide controlled tension. They may be made around specific dimensions, materials, end configurations, load requirements, tolerances, finishes, and application needs.
Does Ace Wire Spring manufacture custom extension springs?
Yes. Ace Wire Spring manufactures custom extension springs to customer specifications for engineers, OEMs, and industrial manufacturers. Extension springs may be quoted from drawings, samples, photos, dimensions, material requirements, end configurations, load requirements, tolerances, and application details.
Can Ace help with extension spring design assistance?
Yes. Ace can provide extension spring design assistance, manufacturing feedback, and production suggestions as part of qualified custom extension spring manufacturing opportunities. Final design responsibility remains with the customer.
Can Ace make prototype extension springs before production?
Yes. Ace can support prototype extension springs and sample production to help customers evaluate fit, pull force, extension, hook configuration, assembly clearance, end performance, and manufacturability before moving into larger production quantities.
What information is needed to quote a custom extension spring?
Customers should provide drawings, samples, photos, dimensions, material requirements, load requirements, end configuration, tolerances, finish requirements, quantities, application details, quality requirements, and expected production needs. More complete information helps Ace prepare a more accurate and timely quote.
Extension Springs are springs which absorb and store energy by offering resistance to a pulling force. Typically, extension springs are made from round wire and are close wound with initial tension. Extension applications include tape cassette players, balance scales, garage doors, washing machines and applications which requiring various types of tensioning devices. Various types of ends are used to attach the extension spring to the source of the force.
Most extension springs are wound with initial tension. This is an internal force that holds the coils tightly together. The measure of the initial force and just start coil separation. Unlike a compression spring, which has zero load at zero deflection, an extension spring can have a prelude at zero deflection.
This build-in load, called initial tension, can be varied within limits, decreasing as the spring index increases. There is a range of stress (and, therefore, force) for any spring index that can be held without problems. If the designer needs an extension spring with no initial tension he should design the spring with space between the coils.
Unlike compression springs, extension springs don’t have a solid stop to prevent overloading. Because of this design stress levels are lower for extension springs than for compression. A special type of extension spring is called a Drawbar spring, it has a solid stop and is a type of compression spring with special hooks.
It is important to include specifications for extension springs in both spring design as well as in placing an order for extension springs. The following information is designed to provide assistance with building specifications for extension springs.
Frequency of Extension. Is Position of Ends important? (Making the ends of springs bear a definite relation to each other usually adds to the cost of manufacture.)
Note: Extension springs made from tempered or hard-drawn wires can be and usually are wound with initial tension. Such tension may average 20% of the total safe stress of the springs, but will not increase the elastic limit.
This video shows how Extension Springs are manufactured.
For more information about extension springs or to talk to one of our experts call 1-800-828-3353.
ACE specializes in custom precision springs and wire forms, offering a distinct advantage by utilizing the most advanced spring design software. ACE validates each existing and new design, notifying the customer with our recommendations.
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