Helical Springs in Manufacturing: Types, Applications, and Custom Spring Solutions

Helical springs are one of the most widely used mechanical components across industrial equipment, automation systems, transportation, medical devices, and firearms manufacturing. Their simple appearance hides the critical role they play in controlling force, absorbing energy, maintaining tension, and ensuring consistent motion in thousands of applications.

Because helical springs are used in both standard and highly specialized equipment, manufacturers often require custom spring specifications to meet precise performance requirements. From prototype development to full scale production, understanding how helical springs function and how to specify them correctly can improve reliability, reduce downtime, and extend product life.

Ace Wire Spring and Form Co. manufactures custom helical springs to customer specifications, supporting a wide range of industries with precision manufacturing and consistent quality.

What Are Helical Springs

A helical spring is a spring formed by coiling wire into a spiral shape. When force is applied, the spring either compresses, extends, or twists depending on its design. The helical shape allows the spring to store mechanical energy and release it in a controlled manner.

Helical springs are most commonly classified into three main types: compression springs, extension springs, and torsion springs. Each type performs a specific mechanical function and is engineered to deliver predictable force across repeated cycles.

Because of their versatility and efficiency, helical springs are found in nearly every industrial sector where controlled motion or load management is required.

Types of Helical Springs and How They Are Used

Compression Helical Springs

Compression springs are designed to resist compressive forces. When a load is applied, the spring shortens and stores energy. Once the load is removed, the spring returns to its original length.

Compression helical springs are commonly used in valves, shock absorption systems, electrical contacts, medical devices, automotive assemblies, and industrial machinery. They are often selected for their ability to handle repeated cycling and deliver consistent force output.

Extension Helical Springs

Extension springs operate in tension. They are designed to stretch when a load is applied and return to their original length when the load is released. These springs typically include hooks or loops on each end for attachment.

Extension helical springs are frequently used in doors, mechanical linkages, balance systems, agricultural equipment, and conveyor mechanisms. Their ability to maintain controlled pulling force makes them ideal for motion control applications.

Torsion Helical Springs

Torsion springs work by twisting rather than compressing or extending. When force is applied, the spring stores rotational energy and releases it when the force is removed.

Torsion helical springs are commonly found in hinges, clamps, lever systems, firearm components, trailer ramps, and industrial equipment assemblies where rotational motion must be controlled.

Why Custom Helical Springs Are Often Required

While standard springs exist, many manufacturing applications require custom helical springs designed to meet specific force, size, and durability requirements. Equipment constraints, environmental exposure, and performance goals often make off the shelf springs unsuitable.

Custom helical springs allow manufacturers to control:

• Spring rate and force output
• Dimensional fit within assemblies
• Material selection for fatigue life and corrosion resistance
• Cycle life performance
• End configurations and mounting features

By designing a spring to match the application rather than forcing an application to match a standard spring, manufacturers achieve better performance, longer service life, and fewer mechanical failures.

Key Design Factors That Affect Helical Spring Performance

Several variables directly impact how a helical spring performs in service.

1. Wire diameter strongly influences spring strength and stress levels. Small changes in wire size can significantly alter spring force.
2. Spring diameter affects both fit and spring rate. A larger diameter generally results in lower stiffness while a smaller diameter increases stiffness.
3. Number of coils determines how flexible the spring is. Fewer coils increase stiffness while more coils decrease it.
4. Free length defines the available travel range and how much force the spring delivers as it deflects.
5. Material choice affects fatigue resistance, corrosion performance, and long term reliability.
6. All of these factors must be balanced to achieve the desired performance without overstressing the spring.

Common Applications of Helical Springs Across Industries

Helical springs are used in nearly every manufacturing sector.

• In industrial machinery, they control motion, absorb shock, and maintain pressure in assemblies.
• In automotive and transportation systems, they support suspension components, braking systems, and vibration control.
• In medical devices, they provide precise force control in compact assemblies where reliability is critical.
• In firearms manufacturing, they regulate feeding, trigger action, recoil control, and safety mechanisms.
• In automation and packaging equipment, they support actuators, conveyors, injectors, and positioning systems.
• This broad usage makes helical springs one of the most searched spring types by engineers and procurement teams.

Material Selection for Helical Springs in Industrial Environments

Choosing the right material is essential for spring life and performance.

• High carbon spring steels are commonly used for strength and fatigue resistance in many industrial applications.
• Stainless steel springs are often selected for corrosion resistance in wet or chemical environments such as food processing, bottling, and medical equipment.
• Specialty alloys may be used where extreme temperatures, high cycle life, or unique mechanical properties are required.

The best material depends on operating conditions, load requirements, and environmental exposure.

Common Helical Spring Failure Causes

When helical springs fail, the most frequent causes include fatigue, corrosion, overstressing, and improper sizing.

• Fatigue occurs when a spring is cycled repeatedly near its stress limits.
• Corrosion weakens the wire surface and accelerates crack formation.
• Overstressing happens when a spring is compressed, extended, or twisted beyond its safe design range.
• Improper sizing can result in unstable operation, buckling, or inconsistent force output.

Understanding these factors during spring specification helps prevent early failures and maintenance issues.

Prototyping and Production of Custom Helical Springs

Many manufacturers require prototype springs during development to test fit, force, and durability. Prototyping allows engineers to fine tune spring performance before committing to production.

Once a design is validated, production manufacturing must maintain tight tolerances and consistent material processing to ensure repeatable performance.

A spring manufacturer that supports both prototypes and production volumes provides continuity and quality control throughout the product lifecycle.

How to Request a Quote for Custom Helical Springs

To receive an accurate quote, manufacturers typically need dimensional details such as wire diameter, spring diameter, free length, coil count, end configuration, and material requirements.

1. Performance targets such as load at specific deflections are also helpful.
2. Photos, drawings, or sample springs can speed up the quoting process and reduce misinterpretation.
3. Providing estimated annual usage helps support production planning and pricing efficiency.

Work With a Custom Helical Spring Manufacturer

If you are sourcing helical springs for industrial equipment, automation systems, transportation assemblies, or specialized machinery, working with an experienced custom spring manufacturer is essential.

Ace Wire Spring and Form Co. manufactures custom helical springs and wire forms to customer specifications, supporting industries that demand tight tolerances, consistent quality, and dependable performance.

Request a Quote for Custom Helical Springs

If your application requires custom helical springs, share your specifications, drawings, or samples to receive a fast and accurate quote. Whether you need prototypes or full production quantities, the right spring design can improve performance and reduce long term maintenance costs.

RJ Froehlich

Ace Wire Spring & Form Co., Inc. is dedicated to educating the world about the critical role springs play in everyday life and industrial innovation. From small mechanisms to large-scale machinery, springs are everywhere—and our mission is to grow our business by helping others understand their importance and potential.

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