We produce custom springs and wireforms. We do not stock standard parts.
We produce custom springs and wireforms. We do not stock standard parts.
Overview: Identifying a Hidden Failure in the Field
At Ace Wire Spring & Form Co., our proactive client engagement doesn’t stop at fulfilling orders—it extends to ensuring our solutions deliver consistent performance under real-world operating conditions.
During a routine customer support visit, an Ace Wire Spring representative observed something unusual at the facility of a major lawncare and agricultural equipment equipment OEM: a box filled with broken extension springs.
This discovery led to a deeper discussion with the buyer, revealing a widespread and escalating issue—springs were failing in the field, resulting in costly warranty claims and mounting frustrations from dealers and distributors.
The problem had drawn the attention of the company’s executive team, including the CEO, who demanded a resolution that would protect the brand’s reputation and restore product reliability. Ace Wire Spring was brought in to analyze, resolve, and redesign a dependable spring solution under tight timelines.
The spring in question was used in riding mower and platform assembly systems, playing a key role in tensioning and actuation. However, premature failures were occurring at a high rate, with springs often breaking at the hook ends after repeated use. These failures led to:
Internal production concerns and growing strain on supplier relationships
While the OEM initially suspected a material flaw—such as inconsistencies in the wire stock or improper heat treatment—the Ace engineering team wanted to perform a thorough analysis before drawing conclusions.
Ace Wire Spring & Form Co. immediately launched a collaborative response involving both failure analysis and design consultation. Our process unfolded in several key phases:
1. Failure Inspection and Field Data Collection
2. Material Testing and Elimination of Wire Defects
Our full Failure Mode and Effects Analysis (FMEA) revealed that the original extension spring design was inherently prone to fatigue due to:
These combined factors led to predictable, high-stress concentration at the hook ends—precisely where failures were occurring in the field.
When the final prototype proved successful, Ace engineers visited the client’s production site to observe the spring’s performance under real operational conditions. These on-site visits allowed for real-time confirmation and final adjustments before transitioning to full-scale production.
The outcome of the custom swivel hook design was immediate and measurable:
This case study highlights the Ace Wire Spring & Form Co. advantage: a combination of deep technical expertise, responsive service, and a hands-on commitment to solving complex mechanical challenges.
When one of the most respected names in industrial lawn care equipment faced mounting product failures and customer dissatisfaction, Ace delivered a reliable, well-engineered solution that restored confidence at every level—from the production floor to executive leadership.
Whether you’re developing new equipment, refining an existing design, or looking to increase the durability of key components, Ace Wire Spring & Form Co. is here to help you engineer smarter, longer-lasting solutions.
With decades of experience supporting high-volume OEMs across lawncare, agricultural, and industrial sectors, we deliver custom spring designs that meet real-world demands, along with the collaborative support and fast turnarounds you need to stay competitive.
Let’s talk about your application requirements and how our engineering team can support your next innovation.
Contact Ace Wire Spring & Form Co. today to start your project with confidence.
"Where it’s always SPRINGTIME!"
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