Accurate, versatile and effective spring design is vital for all industries and sectors. To ensure the best possible outcomes, it’s essential to choose experienced spring manufacturers to design, refine and create reliable components through effective prototyping.

This preliminary stage is vital as it allows for testing and validation of the design’s functionality and performance before mass production, which generates confidence in the results and ensures efficient use of time and money.

Read on to explore the importance of prototyping for spring design and the benefits of our complete service for superior quality spring design, assembly, and finishing results.

Why Is Prototyping Important?

Prototyping accurately represents the final product and enables our clients to visualise how the final product will look before committing to production.

This step reveals any successful elements but, more importantly, any failings that will compromise the spring design later on. Early detection of unforeseen design problems significantly saves resources for the manufacturer and expenses for the client and is a vital start to any efficient manufacturing process.

Using prototypes, designers will test their initial and refined designs, specifications, and materials and easily develop the perfect variation of the desired springs. For example:

  • Spring materials and finishes used in the production must be tested to ensure their strength, durability, and ability to withstand various loads and conditions.
  • The calculated spring rate is also analysed to determine whether it falls within the expected range based on the specific design requirements.

Other specifications, such as spring diameter, wire thickness, and the number of coils, will be tested during prototyping to ensure they meet the design specifications. By thoroughly testing these areas of the design during prototyping, we work closely with our clients to make data-driven decisions that optimise the design for maximum performance, safety and longevity.

Electronic Spring Prototypes

Whilst prototyping is vital for all spring applications, they are particularly important for electronic springs. Testing and ensuring exact specifications for springs in electronics are crucial as they must operate within the intended parameters of their applications and the increasingly confined spaces.

Electronic spring prototype testing similarly involves testing various designed specifications with some common testing, including compression and tension tests and stress analysis.

Spring Design Considerations For Great Results

When it comes to designing and testing an effective spring design, spring manufacturers analyse several specifications that are highly relevant and need to be carefully considered. These specifications ensure the spring performs optimally and meets the required standards.

We have already mentioned spring materials, finishes and spring rates; here are the other key specifications we monitor:

Wire diameter and coil size: When determining the appropriate wire diameter and coil size for the spring, consider load requirements, spring rate, and space limitations to achieve the desired spring characteristics.

The number of active coils: The number of active coils in spring is crucial in determining the spring’s flexibility and deflection.

By selecting the optimal number of coils, we ensure that the spring performs as desired and prevents premature failure. It is essential to match the number of active coils with the specific requirements of your application to avoid under or over-loading the spring. We consider these factors when selecting the optimal number of active coils for your spring, and you’ll receive a spring guaranteed to provide the desired performance.

Stress and fatigue: The stress and fatigue levels springs will encounter during operation are vital to analyse to ensure optimal performance.

The spring must withstand the expected load cycles without excessive stress or fatigue failure. When designing the spring, consider the maximum load capacity it will encounter and the frequency of use. Also, consider the environmental conditions where it will operate, which may influence its performance.

By analysing stress and fatigue levels and ensuring that the spring can withstand the expected load cycles, we design a spring that will operate efficiently and reliably for an extended lifecycle.

Spring End types: When selecting the end types for spring, it is crucial to determine the most suitable options based on factors such as attachment methods, space constraints, and overall functionality.

For example, it’s important to consider whether closed or open ends, hooks, or loops would be the best fit for your specific application. Closed ends provide stability, while open ends offer flexibility. Hooks or loops allow for easy attachment to other components.

Additionally, our engineers will work with you to consider any space limitations that may impact the choice of end types. By carefully considering these factors, we decide on the appropriate end types for the spring, ensuring efficient functionality and compatibility with your intended application.

A Complete Service From Airedale Springs

By choosing Airedale Springs, you have access to a complete spring design service. We offer design, spring assembly, and finishing all under one roof in Keighley, West Yorkshire. This streamlines the prototype and development process, ensuring seamless communication with our clients.

When working with Airedale Springs, you can rest assured that your design concept is in good hands. With our engineering team, thorough testing and modifications take place until you approve a final prototype. Therefore, we guarantee you peace of mind that the final design will meet your application’s requirements and perform as intended. Contact us to get started with our comprehensive services.