We produce custom springs and wireforms. We do not stock standard parts.
We produce custom springs and wireforms. We do not stock standard parts.
In industrial contract manufacturing, even a small component like a spring can impact a project’s success. When production schedules are tight and every part matters, manufacturers need partners who can deliver both speed and precision. At Ace Wire Spring & Form Co., we’re known for stepping in to get the job done where other suppliers hesitate, especially when deadlines are non-negotiable.
This case study highlights how we supported a new customer through the design, prototyping, and production of a custom compression spring made from 3/16″ low-carbon steel wire. From the first inquiry to final delivery, the project took just over a month and included a last-minute dimensional revision. Through clear communication, flexible scheduling, and fast execution, we helped the customer meet their deadlines and launch a new relationship built on trust and performance.
The customer, a contract engineering and manufacturing firm, discovered Ace Wire Spring & Form Co. online and reached out to our general inquiry email with a pressing request.
This company serves large-scale industrial clients by providing custom-built mechanical solutions. Many times, their projects are complex and time-sensitive, and can’t accommodate component delays. This was their first time working with us, and the request was for a custom spring design that needed to be tested quickly and then produced at scale.
The project requirements included:
The springs were being integrated into a larger mechanical assembly, and our customer’s client had a hard delivery deadline. The compression springs had to be manufactured to tight tolerances and delivered quickly in order to meet the demands of the end-user’s timeline.
The success of this project relied on our ability to deliver a quality product under pressure. Key project milestones included:
In just over five weeks, we successfully navigated the quoting process, prototyped a new part, implemented a design revision, and delivered the full production order ahead of our quoted timeline.
Our team responded to the inquiry immediately with a detailed quote within 24 hours. The customer’s design engineer had specific questions about our lead time, spring behavior, and production logistics, so our team engaged in a collaborative discussion to clarify tolerances, lead times, and setup requirements for the coiling process.
To keep production agile, we even prepared our coiler equipment and held it on standby for 24 hours pending customer feedback, ensuring we could move quickly once the client gave us the green light. This type of engineering responsiveness is central to Ace’s support of fast-moving industrial projects.
Once the customer’s internal team approved the design, they placed an order for the initial prototype batch. Within two weeks of booking the order, we had manufactured and shipped the (4) custom springs ahead of the promised delivery date.
The customer received the samples on May 22 and tested them in their assembly by the next day. While our team produced the parts exactly to the original specification, the real-world fit highlighted a minor dimensional issue that impacted alignment. The customer immediately reached out to ask if we could accommodate a minor revision.
Our engineering and production teams reviewed the change and confirmed that we could implement it without affecting production timelines. By the end of the day on May 23, we had the go-ahead to begin full production with the updated specs.
Despite Memorial Day weekend falling during the production window, our team maintained schedule integrity and moved quickly to complete the order.
Using 3/16″ low-carbon steel wire, we produced and inspected all 400 compression springs for consistency, strength, and dimensional accuracy.
The entire production run was shipped by May 30, earlier than initially quoted. The customer received, installed, and shipped their assemblies on time.
Low-carbon steel is a top material for compression springs in industrial applications due to its strength, ductility, and cost-effectiveness. The 3/16″ diameter provided the right combination of structural support and flexibility needed for the customer’s specific assembly requirements.
Because our team works with an extensive range of metals and wire sizes, we were able to accommodate the order quickly without needing to special-order material. This flexibility in sourcing and tooling is one of the reasons we can maintain such quick turnarounds, even on first-time jobs.
For the customer, this project was about finding not only a quality spring but also a reliable supplier they could count on for fast responses, technical clarity, and quality assurance. The experience reinforced our value as more than a spring manufacturer—we were an engineering partner.
At the end of the project:
This project highlights the core strengths of Ace Wire Spring & Form Co., including:
1. Speed Without Sacrificing Precision
We met or exceeded deadlines at every stage, from quoting to production. Even with a dimensional revision midstream, we delivered early.
2. Engineering Collaboration
We communicated directly with the client’s technical team and helped them work through logistics, design adjustments, and material concerns.
3. Flexible Manufacturing
Our readiness to hold equipment on standby and produce revised designs quickly helped avoid bottlenecks and production delays.
4. Strong First Impressions
Our responsiveness and results gave a new customer confidence in our ability to deliver under pressure, an essential trait in contract manufacturing.
At Ace Wire Spring & Form Co., our prototype and sampling services offer customers a distinct advantage not found with typical spring suppliers. Whether you’re refining a new component or troubleshooting an existing design, our in-house engineering team works directly with your drawings and specifications to identify potential tolerance or performance issues before full-scale production.
Unlike companies that offer only standard parts, Ace provides:
As demonstrated in this case study, our ability to quickly produce samples, collect customer feedback, and implement design revisions ensures your part performs as required, helping you avoid production delays and costly errors. This hands-on, collaborative approach sets Ace apart as a true manufacturing partner.
If you’re working on a high-priority project and need a custom spring manufacturer who can perform well under the pressures of modern production timelines, Ace Wire Spring & Form Co. is ready to help.
In addition to our prototyping services, we offer:
Contact our team to discuss your project, request a quote, or learn more about how we support contract manufacturers, OEMs, and industrial engineers nationwide.
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