The manufacturing world is constantly evolving. We have witnessed major changes in the spring industry alone over the past few years as technology has developed and improved. With all these changes, it can be challenging to keep track of what we can expect to see in the future of manufacturing. To help, we have compiled some of the major innovations currently influencing the way we work in the industry.
The Internet of Things
The Internet of Things (IoT) refers to the connectivity between devices that can communicate and exchange data with one another. This technology has enabled greater transparency between stages in the manufacturing supply chain, potentially increasing productivity, and efficiency.
With such impressive reviews, we expect to see the IoT expand within the industry, spreading to each link in the manufacturing chain. In fact, it appears that factories will become ‘smart’ as they begin to utilise smart technology. The UK Industrial IoT market is forecasted to reach £5.63 billion, with more than 62% of UK manufacturers now embracing IoT technologies in their production processes. For spring manufacturers, IoT sensors can monitor wire tension, coiling speeds, and heat treatment temperatures in real-time, ensuring consistent spring quality while reducing waste and energy consumption. Real-time location systems (RTLS) are being leveraged by 43% of manufacturers to track raw materials through the spring production process, from wire drawing to final inspection.
Robotics
The manufacturing line has utilised robotics for a long time, improving efficiency and productivity; however, advancements in this field are sure to be passed on to the broader manufacturing industry. We expect to see advancements in the movement of robotics as they become more human-like and more adaptable. Industrial robot installations in the UK reached a record high, with 3,830 units used in factories across the UK, according to the most recent data from a 2024 study, marking a 51% year-on-year increase.
For spring and wireform manufacturers, collaborative robots (cobots) are projected to experience annual growth of over 30% in the UK, as they excel at precision tasks such as spring sorting, quality inspection, and handling delicate wire forms without compromising product integrity. Despite growth, the UK’s robot density remains at just 101 robots per 10,000 employees, indicating significant automation opportunities for spring manufacturers seeking to improve consistency in coiling operations and reduce manual handling of high-volume production runs.
Virtual & Extended Reality
Virtual reality is quickly becoming incredibly popular within the entertainment industry as gaming and movie technology advances, allowing consumers to immerse themselves in the worlds they play in. However, entertainment isn’t the only application for virtual reality – in fact, this technology is already making its way into the manufacturing industry.
This allows engineers to predict the outcome of practically any situation as they test their products, and even the small parts that go into these products. Predictive analytics are already in use within the industry, but VR enables manufacturers and engineers to take this one step further, ultimately providing a process that is more efficient, more productive, and safer.
We use simulation software at Airedale Springs, which helps us refine the process and design before we start working with real materials. This gives us the ability to ‘predict’ the outcome of our wire forms before they are created; however, virtual reality technology could push this to the next level. The UK’s XR (Extended Reality) market is projected to reach £11.5 billion by 2030, with an annual growth rate of 28.5%. For spring manufacturers, VR enables virtual prototyping of complex wire forms and spring assemblies, allowing engineers to test stress distribution, fatigue life, and assembly processes before committing to physical production.
Industry 4.0 and Smart Factory Integration
Eighty per cent of UK manufacturers are confident that Industry 4.0 will be a reality in their businesses by 2025, with spring manufacturers increasingly adopting automated coiling systems, computerised stress relief ovens, and integrated quality control systems.
The UK Industry 4.0 market generated revenue of £9,478.5 million in 2023 and is projected to reach £30,574.3 million by 2030, presenting significant opportunities for spring designers to invest in advanced CNC coiling equipment and automated finishing processes. With 53% of UK manufacturers already implementing machine learning or AI on the factory floor, spring manufacturers are using AI for predictive maintenance of coiling machines, optimising heat treatment cycles, and ensuring consistent wire feed rates.
Sustainability and Environmental Impact
Manufacturing activities account for 54% of the world’s energy resources and one-fifth of carbon emissions, making sustainability a critical focus for all spring manufacturers in 2025 and beyond.
At Airedale Springs, we exemplify the industry’s commitment to sustainability. We have achieved a Net-Zero CO2 EPC rating of A+ (-12), making us one of the very few manufacturing facilities to reach this standard. Our 181-kW solar panel facility, consisting of 432 panels, provides over 80% of our annual energy needs, supported by a 368-kW battery storage system capable of running operations for over 4 hours. We use 100% recyclable metals for all our springs, wire forms, and pressings, while 90% of our cardboard packaging comes from recycled sources. Through these efforts, we have been recognised with multiple awards, including the 2025 Yorkshire Sustainability Excellence Award in the SME Business Category.
Partner with a Modern Manufacturer
We combine decades of expertise with cutting-edge technology to support British manufacturing. Our investment in modern equipment and sustainable production processes positions us at the forefront of Industry 4.0 adoption.
Contact Airedale Springs today to discuss how our advanced manufacturing capabilities can support your project requirements.