We produce custom springs and wireforms. We do not stock standard parts.
We produce custom springs and wireforms. We do not stock standard parts.
Springs and wire forms are critical components in mechanical, electrical, and industrial systems. At Ace Wire Spring & Form Co., Inc., we produce custom compression, extension, and torsion springs, as well as wire forms, for demanding OEM and utility applications. Below is a step-by-step overview of how precision springs are made — from raw material to finished part.
Every spring begins with the right material. The wire’s composition determines strength, flexibility, and corrosion resistance. Common materials include high-carbon steel, stainless steel, chrome-silicon, and specialty alloys for high-temperature or corrosive environments. The wire is delivered in coils, then straightened, cleaned, and measured for consistent diameter. Precise preparation ensures dimensional accuracy and surface quality before coiling.
Once prepared, the wire is fed into advanced CNC coiling or wire-forming machines. Compression springs are wound around a mandrel to create uniform coils; extension and torsion springs are coiled with specific pitch and end configurations to meet force requirements. Wire forms, on the other hand, are shaped into custom geometries such as hooks, brackets, and linkages. CNC controls maintain consistent coil spacing, pitch, and diameter for precise performance.
During coiling, the wire’s internal structure experiences stress that must be relieved. Springs are heat-treated in temperature-controlled ovens to restore ductility and strength. This process stabilizes the metal, ensuring the spring maintains its load characteristics and shape through repeated use. Depending on the alloy, tempering or annealing is applied to achieve the desired mechanical properties and fatigue resistance.
After heat treatment, additional processes enhance performance. Grinding produces flat, parallel ends that allow compression springs to sit squarely and distribute load evenly. Shot-peening strengthens the surface by introducing compressive stress, improving fatigue life. Setting involves compressing or extending the spring to its working limits, ensuring it maintains the correct free length and tension during operation.
Surface finishing protects the spring from corrosion, improves appearance, and enhances conductivity when needed. Depending on application, finishes may include zinc or nickel plating, phosphate coating, black oxide, powder coating, or passivation for stainless steel. Specialized coatings can be used for electrical or high-temperature environments. Proper finishing extends service life and supports consistent performance in harsh conditions.
Every spring and wire form undergoes thorough inspection to confirm conformance. Measurements include wire diameter, coil diameter, free length, and spring rate. Load testing and visual inspections ensure reliable operation. Springs used in electrical, defense, and aerospace applications may undergo fatigue and plating thickness tests. All parts are produced under Ace Wire Spring’s ISO 9001:2015-certified quality system for traceability and precision.
Once approved, the springs are cleaned, labeled, and packaged for safe shipping. For sensitive applications, protective packaging prevents corrosion or deformation. Each order can be labeled by part number, lot, and date for complete traceability — ensuring easy integration into customer inventory and production systems.
High-performance springs are vital to the reliability of electrical, mechanical, and industrial assemblies. Inadequate material control, inconsistent coiling, or poor finishing can lead to early fatigue or failure. Ace Wire Spring & Form Co., Inc. uses precision CNC machinery, experienced technicians, and proven quality systems to ensure every component meets specification and performs under stress.
Springs and wire forms produced by Ace are used across industries — including electrical switchgear, power generation, transportation, medical devices, and industrial equipment. Our experienced team provides design assistance to help customers match spring geometry, material, and finish to their operational environment. From prototype to production, Ace delivers Made-in-USA precision and reliability.
If your next project requires precision springs or wire forms, contact Ace Wire Spring & Form Co., Inc. today. Our team can assist with material selection, prototype development, and full-scale production for any compression, extension, torsion, or wire-form application.
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