When Precision Matters

Design Tips for Wire Forming

Curious about how to optimize your wire form design? 

At Orlando Precision, we’re committed to helping our customers save time and money on custom springs and wire forms. Today, we’re sharing Design for Manufacturability (DFM) tips for wire forms so you can enjoy faster quotes, shorter lead times, and lower costs. 

We can summarize most of these tips with one general rule: Keep it simple. 

Wire Forms vs. Springs: What’s the Difference? 

Wire forms differ from custom springs in their functionality and how they’re manufactured. Understanding what sets wire forms apart is critical to optimizing their design:

• Function. While springs deform to aid in the movement of an object/assembly, wire forms tend to be rigid and provide stability. There are exceptions, such as designs that incorporate a spring into a wire form, but typically a wire form acts as a frame, clip, handle, or hook and offers support.
• Manufacturing process. Springs are made by either wrapping wire around a mandrel or forcing wire into a coiling point which then create a continuous coil away from the machine, then finally cutting the spring from the machine.

Wire forms are created by feeding a wire a precise distance between two mechanically driven pins, then rotating two pins to create a specific bend angle and radius. This is repeated until all bends have been formed, then the wire form is cut from the machine.

Another important factor to consider is that every wire form is unique in design and function, whereas types of springs (compression, extension, torsion) tend to have similar characteristics.

Designing Wire Forms for Manufacturability

Keeping wire form designs simple will always result in faster manufacturing and lower costs. But what does “simple” mean in the context of custom wire forming? Let’s answer that question by taking a look at a few factors that affect wire form complexity: 

• Bend radius. The bend radius is the measurement inside the wire’s bend to the center of the bending point. Here are some tips for simplifying bend radii specifications in custom wire forming designs: 
• Have one consistent bend radius. It’s possible to achieve two or more bend radii in one wire form. But it can require secondary processes or new tooling, which drive up project costs. If possible, strive to design one consistent bend radius throughout your wire form for more efficient, cost-effective manufacturing.
• Make your bend radius big enough. A bend radius that’s too small can cause cracking on the outside radius of the bend. A good rule of thumb is to keep a 1:1 ratio of bend radius to wire diameter. For example, if a wire has a .25” diameter, the bend radius should be no smaller than .25”. Bigger wires are less forgiving, so the bend radius should be even larger than the wire diameter. This rule of thumb can be broken, but may require testing and prototyping to prove out manufacturability.
• Ensure a distance of at least two wire sizes between bends. Consecutive bends are often impossible to manufacture with standard capabilities. Even when it’s possible to achieve these bends with custom tools, it’s extremely difficult to maintain accuracy. To avoid these difficulties, include adequate space (ideally two wire sizes) between each bend.
• Keep bends in one plane. When possible, avoid complex bends that cross into more than one plane. Wire forms are different from springs, which naturally incorporate bends in more than one plane as the wire is coiled into the spring shape. While complex bends are possible with wire forms, they can increase cost significantly. If they’re not necessary, we recommend designing for single-plane bends instead.  
• Materials. Considerations like end use application and wire form design usually dictate material choice. But if you have some flexibility with your selection, you can save money with cheaper materials. 

Lower tensile strength materials  (around or less than 100,000 psi)  such as basic steels, are easy to work with and inexpensive to source. If your part has long, straight lengths between bends, you’ll need a higher tensile material. 

Let us know your custom wire forming requirements (e.g., corrosion, heat resistance), and we’ll do our best to suggest materials and finishes with budget in mind.

• Tolerances. Many customers are used to designing for precision machining with solid, non-flexible materials, which is a more stable process capable
  of holding extremely tight tolerances. Wire forms require more leniency, both in straight length dimensions and bend angles.  Variation in length and angle is often due to changes in tensile strength throughout a coil, or slight changes in bend angle that can add up with multiple bends. We can generally achieve a tolerance of +/- ½  wire diameter for linear dimensions and +/- 3 degrees for angular, but can achieve tighter tolerances if necessary. The leniency required in tolerancing doesn’t usually affect functionality; it’s offset by the wire form’s flexibility.
• Welding. We always recommend customers avoid welding when possible. Fasteners are preferable to welding because they do not require additional labor, are easy to replace, and can have a cleaner appearance than welded parts. Welding alternatives, such as clips that connect components or overlaps that secure one component to another, are time and cost-efficient options to consider. You can also design a teardrop-eye bend into the wire form to fasten it to another component.

When you need wire forming services, come to the experts at Orlando Precision. Request a quote from us today! 

Are Surface Finishing Operations Necessary for Custom Springs and Wire Forms?

Curious if your custom springs or wire forms need surface finishing operations such as plating or electropolishing? More often than not, they don’t. When alternatives are available, we advise customers to forgo secondary operations when possible to avoid the inherent risks involved in finishing parts.  

Today, we’ll take a closer look at the benefits and risks of common surface finishing operations, as well as some alternatives to finishing custom springs and wire forms. 

Considerations for Surface Finishing Custom Springs and Wire Forms

First, it’s helpful to understand when your custom spring or wire form could benefit from finishing operations:

• Will it be in a corrosive or high-humidity environment? Secondary operations like plating can add a layer of corrosion resistance to help ensure long-term quality and durability.
• Does the part need to be a specific color or meet other aesthetic requirements? Finishes like wet paint and powder coating add color to springs and wire forms. This is often a consideration if the part is easily visible to the end user in the final application.
• Does the part have other specific functional requirements? Some springs and wire forms require plating to increase or decrease electrical conductivity. Others will require grease and debris removal through a passivation process.

If your custom spring or wire form has any of these requirements, we can work with our trusted vendor network to provide finishing operations including: electropolishing, passivation, wet paint, powder coating, zinc plating, nickel plating, black oxide plating, tin plating, and shot peening.

However, there are risks to applying surface finishes to custom springs and wire forms that can jeopardize quality and performance:

• Tangling. Plating and passivation are typically carried out using barrel plating—which involves submerging the parts into a tank of finishing solution, where they roll and tumble around in a chemical bath—can be rough on springs and wire forms, often resulting in uneven solution distribution and potentially causing the parts to tangle and then deform when untangling. This is particularly a concern with smaller wire diameter parts. Rack plating is a much gentler plating method that can minimize the risk of tangling, though it is not cost-effective compared to barrel plating. 
• Arcing. During electrically conductive finishing processes like barrel plating, electrical currents can jump between spring wires, damaging the plated surfaces. Arcing—a type of damage characterized by bubbling welts and rough surfaces—can ultimately lead to breakage.

• Hydrogen embrittlement. In a poorly controlled electroplating environment, hydrogen ions can dissolve into metal during the finishing process, causing the part’s chemical makeup to change. This transformation may result in cracking—known as hydrogen embrittlement—which weakens the molecular structure of the spring. Baking the parts post-plating helps prevent hydrogen embrittlement. We always recommend baking after plating, however this also increases production costs. 

It’s possible to mitigate most of these risks by working with a spring manufacturer that partners with exceptional finishing suppliers – which we do here at Orlando Precision – but there are alternatives to finishing that may be a better option for your application. 

Alternatives to Finishing Custom Springs and Wire Forms

If you need your custom springs or wire forms to resist corrosion, consider using stainless steel wire, which provides corrosion protection comparable to what zinc or nickel plating can offer. 

Another solution is to select pre-plated zinc or galvanized steel wire for your parts. These materials can be difficult to source, but are typically more cost-effective than going the route of secondary surface finish operations. 

If you’ve weighed the risks and determined that you need a surface finish for your custom springs or wire form, indicate the precise specifications using MIL-SPEC or ASTM specs to ensure you receive the exact process that you want. You’ll also need to account for the thickness added by the finishing operation—the spring’s outer diameter will grow slightly, so be sure to factor this added thickness into the part specifications you provide. This added thickness is typically constrained by ASTM specs.

Still wondering if you need a finishing operation for your custom springs or wire forms? Contact Orlando Precision today, and we’ll get your questions answered. 

Designing an Assembly? Don’t Wait Too Long to Design the Spring!

When creating an assembly that contains a spring, you may be accustomed to designing the machined parts first, allocating space in your design for a spring that you’ll add toward the end of the process. 

But saving the spring design for last—or close to it—often leads to problems that can easily be avoided. If you want to ensure that your assembly functions as intended, don’t wait until the last minute to design your spring!

Why Design Custom Springs Earlier in the Process?

Factors like spring size, type, and properties are essential to get right at the beginning of your assembly design. Otherwise, the spring may not fit or function the way you need it to. Consider these unfortunate scenarios that can occur when you wait too long to design the spring:

• Miscalculating the size of the spring and having to sacrifice space in the design—including, at times, important design features—to make it fit
• Designing an entire assembly around the misconception that you needed one custom spring type when you needed another type all along
• Basing an assembly design on a similar product in your current line that has a spring, and then later discovering that the new spring needs to be twice as strong or travel twice as far 
• Having to add weight to an aerospace assembly with strict weight specifications to get the spring to function properly 

We’ve seen these outcomes firsthand far too many times—and we want to help our customers avoid them. 

Designing a spring for your assembly too late in the game can lead to costly redesigns that add many weeks to your lead time, or force you to compromise on essential details, like material and wire thickness, to make your spring work for your design. When you design your spring earlier, you keep your options open to ensure that your assembly design works for you.

Critical Dimensions for Custom Spring Design

Of course, you can’t design a spring in an empty space—it’s impossible to create the right custom spring for an assembly without knowing a few critical dimensions. 

First you’ll need to determine what aspects of the design are most critical. Once you define your constraints, you will be able to design the right spring for your assembly. This could be either dimensional or functional constraints. Some examples include:

• Functional constraints such as moisture or operating temperature will limit which spring materials can be used
• Dimensional constraints such as maximum outer diameter, maximum free length, or minimum compressed length
• Performance constraints such as cycle life, high loading speeds, or sustained loads
• Load constraints are the most common and helpful. Usually 1 or 2 load constraints are required for a spring. This is the force required to compress, extend, or rotate a spring a specific distance. The method to determine this force or movement is different for each type of spring:

• For custom compression springs, determine the compressed length for the specific load
• For custom extension springs, determine the extended length required for the specific load
• For custom torsion springs, determine the rotation angle required for the specific moment

Using this information, you can identify what your spring must do, and what parts of the design are flexible. If you need help with these calculations or want to dig deeper into spring design, contact us at Orlando Precision for assistance and quoting a prototype. 

Have any questions about your spring design? Contact Orlando Precision for support early on in the design process. We’re here to help with all your custom spring design needs!

Need to Replicate a Spring or Wire Form? Inside Our Reverse Engineering Process.

Do you need a spring or wire form but don’t have the original print? Orlando Precision is here to assist.

Our experienced team can often reverse engineer a spring or wire form with nothing more than a sample in hand. We analyze the sample and work with you to determine key specifications and recreate a custom spring or wire form for your application.

Reverse Engineering from Sample Springs and Wire Forms 

Whether you have abundant information about your sample or none at all, we can infer several important details with a close examination of your sample spring or wire form:

• Material. Unsure of your material? We can help to determine the material type. Most springs and wire forms are made of either music wire or stainless steel. We can differentiate between the two by performing magnetic testing to reveal the material’s carbon content. (Music wire has a higher carbon concentration than stainless steel.) 
• Finishing. Without a print, you may not know if your sample was plated for corrosion resistance or other purposes. We’ll make an assessment, then work with you to ensure the proposed finish meets all functionality requirements.
• Tolerances. We excel at manufacturing precision springs and wire forms, so if you require precision tolerances, we’ll make sure that your part achieves them. We manufacture all springs to the Spring Manufacturer Institute’s commercial tolerances at a minimum.

Replicating Spring and Wire Form Functionality 

Although we can learn quite a bit about your spring or wire form through a physical examination and basic testing, we’ll need more information from you about its functionality and intended application.

If you need a compression spring replicated, let us know how far the spring compresses in its application and if a specific force or spring rate is required. If you need an extension spring, let us know how far it will need to extend. And if you need a torsion spring replicated, tell us what angle the spring is installed and how far it rotates in application and if a specific torque is needed.

The more information you provide, the better equipped we are to manufacture the spring or wire form you need.

Optimizing a Replicated Spring or Wire Form

Reverse engineering springs and wire forms provides an excellent opportunity to review and assess the original design. You may be able to make changes in the design that could improve functionality, save money, or both.

If you want to optimize your spring, we’ll run a design check to reveal weak points that may cause your spring to become overstressed or prone to failure, then adjust those areas of concern. If your replacement spring needs a complete overhaul, consider our spring prototyping services to start the design process from scratch.

Reviewing your design may also present ways to cut costs. If, for instance, we find that operations like grinding aren’t critical for functionality, we can save you the extra expense. For wire forms, we often suggest small design changes to increase production speeds or reduce tooling costs.

Orlando Precision is here for all your reverse engineering needs. Request a quote from our custom spring and wire form experts today! 

Choosing the Right Custom Compression Spring

Does your part require a spring that compresses with applied force? If so, you probably need a compression spring.

A standard, cylindrical compression spring might do the trick. These springs are ideal for most conventional applications requiring a constant spring rate.

But suppose you need a compression spring that provides more structural support, like one that can prevent a hose from kinking when coiled. In that case, you might need a less common type of compression spring.

The good news is you have a wide range of options to choose from. A custom compression spring manufacturer like Orlando Precision can help you make the right selection for your application.

3 Compression Spring Styles You Might Not Know About

These 3 types of compression springs offer unique benefits that might suit your application better than a standard cylindrical compression spring:

Conical compression spring. These cone-shaped compression springs coil in increasing or decreasing outer diameters. Unlike a cylindrical compression spring, a conical spring does not provide a constant spring rate, allowing for specific loads to be achieved at specific compressed lengths.

Conical compression springs can collapse to a completely flat shape. This feature is useful for spring applications requiring a small solid height, like battery contacts or push buttons.

Hourglass compression spring. Also known as concave springs, hourglass compression springs have large diameter end coils and smaller diameter middle coils that create their signature shape. Hourglass compression springs behave almost as two conical springs pressed end to end, also allowing for a low profile when compressed to solid height.

While an uncommon style, an hourglass spring is often chosen to fit within a specific hole size or to prevent buckling.

Barrel compression spring. These convex springs have wider coils in the center than on the ends, making them sturdier than cylindrical springs. Like hourglass compression springs, they typically won’t buckle when compressed.

Unlike conical springs that can easily collapse, barrel compression springs require much more force to compress and don’t easily compress to solid height. Many barrel springs are not used for their spring properties, and instead are used as a handle to provide comfortable grip or heat resistance with a hot object.

Compression Spring Considerations

Here are several key factors to consider when selecting a compression spring: 

• Variable pitch. The distance between each coil—known as the pitch—directly affects the spring rate. Most compression springs have a constant pitch and spring rate, but some designs will require a variable pitch to provide a non-constant spring rate. It’s important to select a spring that provides the right spring rate for your application.
• Dead coils. To increase the length of a spring while maintaining spring rate and travel length, you may choose to add dead coils—adjacent coils with no spacing when the spring is at its maximum loaded height. When compressed, these coils are inactive and do not affect the active coils of the spring.
• Closed vs. open ends. Nearly all compression springs are closed on either end to sit flat. However, in rare instances, certain applications may need open-ended springs that require support from a rod or tube to stand upright. Open springs do not offer a flat surface to compress against and tend to tangle, so they’re uncommon in most applications.
• Ground ends. Grinding the ends of a compression spring on a grinding wheel is a great way to achieve an even flatter surface. Finished ends increase stability and allow for maximum contact surface area.

Not sure which type of spring you need? Talk through your options with a custom compression spring manufacturer. Consult the specialists at Orlando Precision today! 

The Value of Working with an ISO Certified Spring Manufacturer

When you need custom precision springs or wireforms for high-stakes industries like aerospace or defense, there’s no compromising on quality. These products serve a critical purpose in high-risk applications, so they must function exactly as intended. 

Since 2016, Orlando Precision has been an ISO 9001:2015 certified manufacturer. This certification indicates that our Quality Management System has been determined to meet the ISO standards for consistency and continual improvement.

At Orlando Precision, being ISO certified is more than checking a box. Quality is our purpose – it is behind every product commitment we make to our customers.

What It Takes to Be an ISO 9001:2015 Certified Spring Manufacturer 

All of our customers in the many industries we serve benefit from our quality standards:

• Documented processes. We carefully document each step of production, from material sourcing to part tracking. This ensures the repeatability and consistency that are vital to satisfy our customers for every order.
• Rigorous inspections. Before advancing a  part from prototype into production, we closely inspect all critical features to ensure that we’ve met all specifications and manufactured to print. We conduct first part inspection, in-process, final part inspections, and First Article Inspections as appropriate and required for each order.
• Carefully vetted vendors. We require ISO 9001:2015 or higher certification or a thorough quality evaluation from each of our vendors, raw material providers, and outside finishing services. We continually monitor each vendor’s quality and on-time delivery to ensure we can continue to exceed our customer’s expectations.
• Measurable goals. ISO certification sets baseline standards for quality management, but baseline has never been good enough for us. We set our standards well above the norm and do whatever it takes to follow through. For instance, we consistently deliver each of our orders on time with 99-100% accuracy, which isn’t an ISO requirement. We’re proud to have a customer return rate of less than 1%.
• Quality audits. We have an annual quality audit that is conducted both internally and through a third party. Auditors define specific areas to review and also spot-check others to make sure we’re meeting all quality standards. They evaluate each of our processes, from our method of tracking and cataloguing incoming orders to our system of receiving payments—and everything in between. 

We are proud to be an ISO 9001:2015 certified spring and wire form manufacturer, but ISO certification is only a starting place for monitoring and improving our quality systems. Excelling beyond those standards required steadfast internal review and a commitment to setting and achieving the highest possible goals. When a procedure or activity results in us not meeting one of our standards, we create an immediate action plan to improve it.

When you need a high-quality custom precision spring or wire form, you can depend on Orlando Precision Company to deliver. Request a quote today – we look forward to working with you!

Do You Need a Custom Spring or a Stock Spring?

So you designed a part that needs a spring. Now all you have to do is figure out how to source it. Simple, right?

Well, not exactly. If you don’t work with springs all the time, how do you know whether to stop by your local hardware store, order from a stock spring catalog, or visit a custom spring manufacturer? 

Let’s break down the options.

Benefits and Drawbacks of Using Stock Springs

If you’re in the early stages of prototyping or working on a part that was designed to accommodate standard spring specifications, you may want to consider using stock springs.

In most cases, your local hardware store won’t have the kind of spring you need. We recommend ordering from an online stock spring catalogue instead. 

Stock spring catalogues offer a wide variety of standard springs to choose from—but you should know the benefits and drawbacks of this solution before moving forward. 

Benefits of using stock springs: 

• Low cost. It’s possible to order 1, 5, or even 10 springs online with a fairly minimal budget. Keeping costs low is ideal when you’re testing several springs to determine the approximate dimensions that work best for an application.
• Easy to source. If your design accommodates a standard spring or a MIL-SPEC compression spring for loads under 20 lbs., you’ll find exactly what you’re looking for in a stock catalogue. Stock springs are generally readily available.
• Fast turnaround. Because standard springs are held in inventory, ordering from a stock spring catalogue is quicker than having your spring custom made. 

Drawbacks of using stock springs: 

• Limited options. If you have non-standard measurements for dimensions such as spring length, outer diameter, or spring rate, you may not find the right solution in a spring catalogue. Remember, stock springs are made to standard specs—not yours! Likewise, if you’re looking for a custom material or finish, a stock spring may not be the right choice.
• Cost-prohibitive at volume. Stock springs are cost-effective when you only need small quantities—from one up to a few dozen. However, if you require a higher volume of parts, custom springs often end up being more cost-effective than stock options.
• Difficult to trace. If your project requires documentation with clear material traceability, you should know that this information may be difficult to acquire with a stock spring. Some documentation may be available online or from the manufacturer, but it’s not always easy to find. 

When to Use Custom Springs Instead

If you’re unsure whether a stock spring will meet your needs, it’s probably time to call a custom precision spring manufacturer. If you’re still on the fence, here are a few questions that can help you determine if a custom spring is best for your design:

• Do I need to hold a specific dimension or spring rate? First, check online to see if there’s a stock option for your wire size, diameter, and length requirements. If you can’t find what you’re looking for, you’ll probably need a custom spring. 
• Do I need more than 100 springs? Customers who need a higher volume of springs—again, “high volume” can be as little as a few dozen springs—typically benefit from placing an order with a custom spring shop instead of a stock manufacturer. So even if your spring is available in a stock size, you may still want to choose custom spring manufacturing for the cost benefits.
• Does my spring have tight tolerance requirements? Stock springs typically hold to standard commercial tolerance requirements as defined by the Spring Manufacturers Institute (SMI). But if you need tighter tolerances than that, a custom precision spring is the best way to guarantee them.
• Do I need a specific load height? Load height, a specific force required to achieve a specific compressed/extended length, may not be a critical requirement for your application. But if you do need a specific load height that is verified during production, it’s usually only achievable with a custom spring. 
• Do I need an extension or torsion spring? Compression springs are generally easiest to source from stock. Extension and torsion springs, on the other hand, can be more difficult to find. Extension springs are often designed with unique spring hooks, and torsion springs may require specific angles between the legs, making these types of springs excellent candidates for customization. 

When you need a custom spring, you can trust Orlando Precision to deliver. Request a quote today! 

Orlando Spring announces the acquisition of the metal stamping assets of Advanex Americas (formerly known as Electronic Stamping)

Orlando Spring Corporation, a leading provider of highly engineered springs, machined parts, wire forms, and other precision components for the aerospace, medical, electronics, and defense industries, announced today the acquisition of the metal stamping assets of Advanex Americas, greatly expanding Orlando Spring’s stamping capabilities.

Advanex Americas acquired Electronic Stamping approximately 5 years ago and has been proudly serving the aerospace and electronics industries with stamped metal parts during this period. The acquired assets feature a wide array of capabilities including reel to reel stamped parts in medium and high volume, progressive stampings, single stage stampings, and capacity to go up to 110 ton presses.

”Orlando Spring and its affiliated family of companies, Fibreform Precision Machining and Delta Machine Company, will now be able to offer customers a broader base of products and in higher volumes,” explains Frank Mauro, President, Orlando Spring Corporation.

The stamping assets will immediately relocate to the larger Orlando Spring facility in Huntington Beach.

About Orlando Spring

Orlando Spring is grounded in experience and forward-thinking in its approach. Founded in 1957, the company was acquired in 2009 by Crosse Partners, an established equity partnership, in order to grow and establish Orlando Spring’s exceptional reputation in the industry. Orlando Spring is quickly becoming the leader in vertically integrated, custom spring and wire-form manufacturing for aerospace, medical, electronic, and defense industries.

About Fibreform Precision Machining

Since 1958, Fibreform Precision Machining has become one of the leading Precision Machining companies for the aerospace and defense industries. With its ability to meet tight tolerance applications through advanced manufacturing techniques as well as jig bore capability, Fibreform is one of the top supply chain partners to OEMs, Tier I, and Tier II organizations.

About Delta Machine Company

Since 1980, Delta Machine Company, LLC. has been specializing in precision machining for the Aerospace, Defense, Automotive, Medical, and Commercial industries. Their extensive experience in machining complicated, tight tolerance parts out of Titanium, Stainless Steels, Inconel, and other superalloys/exotic materials along with their unparalleled experience with castings, forgings, and sintered parts makes them a highly sought-after machine shop.

If you have any questions, please contact customer service at the following:

Phone: 562-594-8411

E-mail: osc@orlandospring.com

To receive more information please contact Frank Mauro, President, at 562-594-8411 or e-mail fmauro@orlandospring.com.  More information is also available on the Orlando Spring, Fibreform, and Delta websites:

www.orlandospring.com

www.fibreformprecision.com

www.deltamachineco.com

LOCATION:

5341 Argosy Ave.

Huntington Beach, CA 92649

6 Common Applications for Custom Wire Forms

You know us as Orlando Precision, but there’s more to us than our name may imply. In addition to making springs, we also make custom precision wire forms!

Typically formed from round wire, wire forms can be manufactured to fit customers’ needs, no matter how complex. They’re found in wide range of items, from military equipment and aircraft seating, to napkin holders, handles, and hooks. 

We have the expertise—to manufacture custom wire forms for a wide range of customer applications. 

Benefits of Choosing a Wire Form

Other manufacturing methods, such as injection molding and machining, can achieve an end part with similar functionality as a custom wire form. However, depending on the number of parts you need, other methods of manufacturing can be cost-prohibitive, making wire-forming a great choice for prototyping or low-volume production.

Here are some additional benefits you’ll get from choosing a custom wire form: 

• Easy access attachment points for quick assembly
• Inexpensive and easy to machine
• Material flexibility and spring-like behavior
• Easy to customize and mold to the shape of whatever it’s holding
• Better stress absorbing properties than plastic

6 Common Applications for Wire Forming

Curious as to how you can incorporate wire forms into your next design? Here are some common wire forming applications: 

1. Frames. Wire forms provide structural support and add reinforcement to products made with softer materials such as upholstery. For example, the aerospace industry might require a wireform to reinforce the fabric for airplane seating.
2. Hangers. Hooks, hangers, and other similar applications are well suited for wire forming.
3. Handles. If you need to attach a handle to a product, wire forming is a great solution and easy to assemble option.
4. Support structures. We use the fully customizable properties of wire forms to build support structures for weighted objects. We’ve manufactured table stands for tablets and wall-mounted supports for gaming controllers with one-of-a-kind wire forms.
5. Spring-like applications. When you need a part with spring-like properties, such as the ability to exert pressure while maintaining flexibility, you might be able to use a wire form instead. Torsion or extension springs can even be incorporated into wire forms in some instances. 
6. Rings. Basic rings or clips are simple shapes that can easily be formed with wire. 

 

When you need a custom wire form, look no further than Orlando Precision. Our CNC 3D wire bending equipment guarantees manufacturing repeatability and maintains high precision. Request a quote for your custom wireform today! 

Choosing the Right Material for Your Custom Spring

Do you know the right material for your custom spring? 

Technically, it’s possible to make a spring out of nearly any manufacturable material. But just because a material can be used for a spring doesn’t mean that it should be. 

Not all materials can withstand the repetition and pressure that springs are subject to in the field. That’s why it’s important to find the right material for the type of precision spring your project needs.

If you’re not sure which material to choose or want to learn about the various options, we’re happy to explain it to you: 

Common Materials for Custom Springs

Here’s a look at some of the most common materials used for custom springs: 

Music wire

Made out of basic carbon spring steel, music wire is by far the most commonly used spring material. It’s a cost-effective option that boasts strong performance for the price. Music wire holds up well under somewhat high temperature conditions, functioning well at temperatures of up to 200 degrees Fahrenheit.

It’s important to note, however, that carbon steel is not corrosion resistant. Therefore, we don’t typically recommend music wire for outdoor applications or wet environments without a finish or coating to provide additional protection.

Stainless steel

When you need better corrosion resistance and functionality while your spring is exposed to high heat, stainless steel is usually the go-to option. Stainless steels are more expensive than basic steels, however using them often removes the need for secondary finish processes. There are a few grades of stainless steel for custom springs to choose from, including:

• 302 stainless steel. This standard stainless steel option is the most common; it has higher heat resistance and slightly less strength than music wire.

• 316 stainless steel. If you need a food-grade or cleanroom quality material with additional corrosion-resistant properties, 316 stainless steel is an excellent choice. This grade of stainless steel also offers a slightly higher heat resistance than 302 stainless steel.

• 17-7 stainless steel. The ultimate heat-resistant stainless spring material, 17-7 stainless steel can withstand temperatures of up to 600 degrees Fahrenheit and handle much greater stress than its other stainless steel counterparts.

Inconel X

Inconel X is used far less frequently than music wire or stainless steel—in part because it’s much more expensive. However, Inconel X can be a good choice for a small number of applications. This exotic material can withstand extremely high temperatures up to 1,100 degrees Fahrenheit. 

Other materials 

Other material options like brass, beryllium copper, and phosphor bronze are even less common, which make them more expensive and harder to source. These specialty materials are selected for specific properties such as: magnetic properties, corrosion resistance, electrical conductivity, resistance to acidic environments, or resistance to salt water environments.

While metal is considered the standard material for custom springs, 3D printers have recently begun producing plastic springs as well. 

How to Choose a Precision Spring Material

Now that you know the most common spring materials, consider these factors when choosing the right one for your custom spring: 

• Operating environment. Springs have different needs depending on the environment they’re operating in. Will the spring be in an outdoor application with high humidity? If so, you’ll need a corrosion-resistant material like stainless steel or plated music wire. Will the spring be subject to extreme temperatures? High heat environments may require special materials or heat treating.

• Number of spring cycles. Springs are designed to withstand many cycles of use without losing strength or failing. If your spring will need to endure millions of cycles during its lifetime, consider a high-tensile material with a long fatigue life that’s capable of handling repetition. 

• Strength and flexibility. How much room does your spring have to compress or extend? Choose your material with dimensional constraints in mind. Using a high-tensile strength material will get you more strength out of the space the spring is in.

• Cost. Material costs are always a determining factor—especially at production volumes. But keep in mind that there’s a tradeoff between price and quality of material: any higher quality material is typically going to cost more and be more difficult to source, but it may be worth the price. A material like 316 stainless steel, for example, can help prevent corrosion, minimize stress, and even fight bacteria. 

No matter your spring needs, Orlando Precision can help find a suitable material for you. It all starts with a conversation. Whether you need a spring designed from scratch or reverse engineered, hearing about your spring’s application helps us recommend the best material for you. 

Request a quote for your custom spring today! 

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