Case Studies: How Ace Wire Spring Solved The Problem

Real-World Solutions from Ace Wire Spring & Form Co., Inc.

Discover how Ace Wire Spring & Form Co., Inc. engineers and manufactures custom springs and precision wire forms that solve complex design and production challenges across multiple industries.

Since 1939, Ace has supported manufacturers nationwide with custom compression springs, extension springs, torsion springs, and wire forms built for performance, precision, and durability. Our engineering team frequently steps in when deadlines are tight, tolerances are critical, and reliability cannot be compromised.

These featured case studies highlight Ace’s ability to deliver rapid prototyping, design collaboration, and dependable long-term manufacturing support for OEMs in lawncare, agriculture, conveyor systems, trailers, power generation, and medical equipment.

Agricultural Industry – Tine Problem to Spring Solution

A leading lawncare OEM was experiencing widespread field failures from extension springs on riding mower assemblies, triggering costly warranty claims and dealer frustration. Ace Wire Spring analyzed the failures, ruled out material defects, and engineered a custom swivel-hook extension spring that restored reliability—eliminating spring-related failures, ending warranty issues, and converting the OEM to an approved-vendor partnership with 11 sourced components since 2016. Read The Complete Case Study

Capabilities Demonstrated:

• Rapid reverse-engineering and sample analysis

• Custom tooling and precision heat treatment

• Reliable low-volume manufacturing for legacy components

• Proven field performance equal to OEM standards

Lawncare Equipment Industry – Solving Extension Spring Failures

A major lawncare equipment OEM faced recurring extension spring failures in its riding mower assemblies, leading to warranty claims and dealer dissatisfaction. Ace Wire Spring investigated the issue, ruled out material defects, and engineered a custom swivel-hook extension spring that restored reliability and performance. The new design eliminated spring-related failures and secured Ace as a long-term vendor, now providing 11 sourced components since 2016. Read The Complete Case Study

Capabilities Demonstrated:

• Engineering analysis and failure root-cause determination

• Custom spring design and performance optimization

• Production scalability for OEM supply

• Long-term vendor partnership development

Industrial Manufacturing – Fast Custom Compression Spring Production

A new contract manufacturing customer required a custom compression spring in 3/16″ low-carbon steel and needed a complete prototype-to-production turnaround in just over five weeks. Ace Wire Spring provided engineering collaboration, sample production ahead of schedule, and accommodated a last-minute dimensional change without delay—shipping all 400 production parts early. Read The Complete Case Study

Capabilities Demonstrated:

• Rapid quoting and design validation

• Flexible, fast-turnaround manufacturing processes

• Prototype-to-production transition within five weeks

• Customer-focused responsiveness and adaptability

Why These Case Studies Matter

Each success story underscores Ace Wire Spring’s ability to combine engineering support, custom tooling, and manufacturing precision to deliver consistent results. Whether you need custom trailer springs, wire forms for conveyor systems, or precision components for medical assemblies, Ace’s experience across multiple industries ensures that every part performs as expected.

• Explore more about our industries served
• Request a quote for your next custom spring project