We produce custom springs and wireforms. We do not stock standard parts.
We produce custom springs and wireforms. We do not stock standard parts.
A manufacturer in the electrification and power distribution industry needed a supplier capable of producing a highly specialized spring for use inside an electrical switchgear assembly. The component required extremely small material dimensions, precise load characteristics, and careful technical review before production could move forward.
After finding Ace Wire Spring & Form Co. through an online search, the customer submitted a quote request via the company website. What began as an inquiry for one miniature spring evolved into a broader supplier relationship, with Ace now supporting multiple spring components used in the customer’s electrical assemblies.
The customer’s immediate need centered on a spring used within a switchgear assembly. They provided drawings and requested prototype samples on a tight timeline to evaluate the component before committing to production.
During the initial review, Ace identified several factors that made the project especially demanding. The spring material measured approximately 0.001 inch thick by 0.012 inch wide, creating a significant manufacturing challenge due to its extremely thin thickness and the tight functional requirements of the application.
Because the customer used this spring within a complex electrical component, the part needed to meet precise load characteristics and dimensional requirements. Because this was not a standard spring application, it required careful engineering review to determine whether the design could be produced consistently and perform reliably in the finished assembly.
After discovering Ace online, the customer submitted a quote request via the website, including drawings of the spring component and a request for prototype support. The timeline was tight, and the application called for a supplier that could move quickly while still evaluating the part’s technical requirements.
Ace reviewed the inquiry and recognized that this would require collaboration across estimating, engineering, and quality to confirm feasibility.
Engineering Review and Cross-Functional Collaboration
Once Ace received the drawings and a physical sample, the team began a detailed review of the design. The physical sample arrived partially dislodged during transit, which made direct evaluation more difficult. Rather than relying on incomplete information, Ace worked closely with the customer to gather the missing technical details needed to move the project forward, including gathering clarification on:
Because of the application’s complexity, Ace’s engineering team carefully analyzed whether the required load characteristics and tolerances could be achieved in a repeatable production process. Ace prioritized quality throughout the review to help ensure that any proposed solution would align with both manufacturing capability and functional performance.
The customer wanted prototype samples to validate performance before committing to production quantities, and Ace supported that process. The Ace team prepared quotations for the initial components and reviewed additional components from the customer’s broader product line.
This approach ensured the project moved forward without losing momentum. It also positioned Ace not only as a potential source for the first spring but as a possible long-term supplier for additional electrical spring components as the relationship developed.
During discussions, the customer indicated an estimated annual usage of 75,000 to 80,000 springs for the initial component. They also noted that approximately twenty additional spring components could be sourced in the future.
That made it important to evaluate not only prototype feasibility but also the project’s long-term production potential. Ace’s review considered both the technical challenge of the miniature spring and the ability to support meaningful production volumes for an electrical equipment manufacturer.
Through technical collaboration, engineering review, and prototype support, Ace demonstrated the ability to manufacture the required miniature spring component. The project showed that even with very small dimensions and tight functional requirements, the part could be evaluated and developed with a structured engineering approach.
After the prototype and evaluation process, the customer moved forward with Ace as a supplier for several electrical spring components used in their switchgear products. The successful validation stage gave the customer confidence in both the part and the process.
What began as a request for one specialized spring developed into a broader working relationship. Following the initial success, the customer expanded its sourcing with Ace and established Ace as a supplier of multiple spring components used in electrical assemblies.
This kind of growth reflects more than the ability to make a single part. It shows the value of technical communication, careful feasibility review, and reliable support during early-stage development.
This project highlights several capabilities that are especially relevant for manufacturers in the electrification and power distribution space.
Ace demonstrated the ability to manufacture extremely small and precise spring components while reviewing complex load requirements and collaborating closely with the customer’s engineering team to clarify application details. The project also demonstrated Ace’s ability to support prototype validation and prepare for production volumes that align with the demands of electrical equipment manufacturing.
For this electrical switchgear manufacturer, the challenge went beyond simply finding a spring supplier. They needed a partner that could evaluate a miniature, technically demanding component, collaborate through missing or incomplete sample information, and support prototype testing under a tight timeline.
Ace Wire Spring & Form Co. helped move the project from inquiry to evaluation to production support, ultimately becoming a supplier for multiple spring components used in the customer’s switchgear assemblies.
Ace continues to support manufacturers in the electrification industry with precision spring solutions, engineering collaboration, and scalable production for complex electrical applications.
Looking for a supplier for miniature springs or other custom electrical components?
Contact Ace Wire Spring & Form Co. to discuss your application.
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