Author: European Springs Web Team

Manufacturing springs is a complex and precise process. At European Springs Ireland, we take great pride in producing high-quality components that consistently exceed customer expectations. In this blog, we’ll explore how springs are made and how we incorporate advanced technology and rigorous quality control throughout our production process. 

The Manufacturing Process 

The journey begins with a design consultation, during which we work closely with our clients to fully understand their requirements and the specific applications for the springs. Our experienced engineers maintain clear and consistent communication to ensure that every product is accurately designed and perfectly suited to its intended use. 

Following the consultation, we carefully select the most appropriate material based on the client’s industry and application needs. Material selection is a critical factor in spring manufacturing, directly influencing performance, longevity, and reliability. 

We offer a range of high-quality materials, including:  

  • Carbon Steel: Carbon steel is known for its strong and adaptable material. It is suitable for a wide range of applications, such as general purpose springs. 
  • Stainless Steel: This material is corrosion resistant and is commonly used in harsh environments with exposure to moisture or chemicals.  
  • Special Alloys: We also offer speciality alloys that provide unique properties, such as high-temperature resistance or enhanced fatigue life. These materials are tailored for applications that require exceptional performance. 

Once the appropriate material has been selected for the spring design, we move on to the sampling stage. This phase is essential to ensure the design meets the client’s expectations and to identify any necessary adjustments before progressing to full-scale production. Our expert team produces mock-up components that closely replicate the final product.  

During the prototyping stage, we conduct thorough testing procedures, including load testing, to verify that the spring can endure the required forces. These tests also help to detect any design issues that may need to be refined. In addition, we carry out precise inspections to confirm that the sample matches the intended size and shape, which is vital to ensure that the spring functions correctly in its application. 

We place great importance on customer feedback throughout the entire process, especially during the prototyping phase. This collaborative approach allows us to refine the design if needed, ensuring that the spring fully meets your requirements. Ongoing communication helps guarantee that the final product aligns perfectly with expectations.  

If no changes need to be made and the sample piece has been approved, we can start our manufacturing process. This starts with bending the wire into the desired form using advanced technology and machinery. Our high-tech equipment allows us to create springs in many different sizes and shapes accurately.  

Spring wiring is the first step of the sprig manufacturing process, which is what gives springs their coiled, spiral shape. At European Springs Ireland, we use three main machines to help us with this process, this includes: 

  • Coiling Machine: Spring coiler machine is used by feeding the wire through the rollers until it peaks at a coiling point. The wire can then be coiled back to form the spring. These machines are most suitable for manufacturing of torsion, tension and compression springs.  
  • Forming Machine: A spring machine is more adaptable than coiling machine. It allows it to create bends, which means more spring types can be created with this kind of machine.  
  • Bending Machine: We utilise computer-led CNC bending machines as they offer specially placed rollers to help create bespoke wire forms for all our clients requesting bespoke solutions.  

After wiring and coiling, we can move on to heat treating. This step is crucial as it makes springs stronger, more durable, and enhance elasticity, making them more resistant to wear and tear. It will also make forming and manufacturing the material easier later on in the process, as it minimises the risk of cracking and distorting.  

Next, to improve performance and durability even further, we employ coating and finishes to make sure that the spring is reliable. Here are the different types of coating and finishing technologies that we use during our spring manufacturing process: 

  • Shoot peening: This is a type of surface treatment that gives metal strength and creates a fatigue-resisting layer of compressive stress.  
  • Plating: This can enhance both how the spring looks and improve their performance as well. This can enhance appearance and improve resistance to wear and tear.   
  • Powder coating: A dry finishing process in which powder is electrostatically charged, sprayed onto the surface, and heated. This causes the powder to melt and form a durable layer that protects against corrosion and other environmental factors.  

The final step that we make sure to do is quality control. This is crucial in our manufacturing process to make sure that each spring that has been created has no faults and that it meets our high standards. Our quality procedures include dimensional checks, material testing and fatigue testing. Assessing these factors ensures that the spring can withstand the stress of its applications and that its overall usage will be suitable for the specific application. 

The quality of any product is heavily impacted by the procedures carried out during production, which is why we carry out careful and detailed manufacturing procedures to minimise damage and enhance longevity.  

In summary, the team make sure to carefully plan in detail the use of high-quality materials, advanced tech and thorough quality control in order to produce reliable and effective components that all our customers look for. We are dedicated to making constant improvements in everything that we do to ensure you get the best results. To find out more about what we have to offer, or if you have any enquiries on bespoke spring solutions, make sure to contact us today, and we will be happy to assist.  

 

The applications of springs are vast, spanning healthcare, manufacturing, and the automotive industry, where they serve a wide range of essential functions. They are even found in spacecraft systems, including satellites and robotics, playing a crucial role in advanced mechanisms.

In this blog, we will explore the diverse applications of springs and pressings in space exploration, highlighting their vital role in ensuring precision, reliability, and control in extreme environments. At European Springs Ireland, we tailor our products to meet the demands of various sectors, including the aerospace industry, guaranteeing longevity and exceptional performance in every component.

The Challenges of Springs in Space

It’s unsurprising that there are several challenges for the components that make it to outer space, as they’re exposed to a different set of environmental conditions. There are several considerations and obstacles that springs in space have to overcome; here are just a few examples:

  • Gravity: In space, springs are required to function reliably without gravity, meaning that they have to be constructed to work based on force application rather than reacting to gravity as they do on Earth. Springs can experience reduced extension and compression due to the lack of gravitational force and can expand or contract more freely, which can impact the overall spring’s performance. Moreover, the spring constant, a key factor in determining the stiffness of a spring can also experience changes in space. This is due to a lack of gravitational force, meaning that the spring’s weight doesn’t contribute to the force exerted, so the spring constant may need adjusting to reach desired levels of force when in space.
  • Temperature: In space, springs are subject to drastically different temperatures than on Earth, in both extremely cold and hot variations. Springs, therefore, need to be constructed with these considerations in mind to ensure reliable performance in outer space. Special coatings and certain spring materials adapted to these conditions can be utilised by spring manufacturers for this application.
  • Degradation: There are certain environmental factors that can lead to spring degradation whilst operating in space, such as cosmic and solar radiation. Degradation overtime from these environmental conditions leads to changes in the spring’s mechanical properties. They can become more brittle or experience a reduction in elasticity, which influences their effectiveness.

These are just a few challenges spring designers face when crafting components to be used in this extreme environment, there are even more obstacles to overcome depending on the application.

The Mars Rover: Springs on Other Planets

Springs have played an essential role in the Mars Rover missions, from the early Sojourner rover to the more recent Curiosity and Perseverance rovers, spring technology is consistently evolving to meet the extreme conditions of Mars. For instance, the Rocker-Bogie suspension system uses compression springs, maintaining stability and mobility across the rough terrain of Mars. This system was originally employed in the Sojourner rover and has been improved on in following missions.

The design and development of these springs were challenging, as manufacturers had to consider temperature fluctuations and Mars’ rugged surface. Advanced materials like memory alloys were experimented with to provide a reliable solution that could work under such demands. Springs used on these missions were tested and simulated on Earth in replicated Martian environments to check if these springs could maintain flexibility and absorb shock adequately.

The impact of these innovations goes beyond space exploration. The technologies developed for the Mars rovers are now influencing industries on Earth, such as the aerospace and automotive sectors.

The Juno Mission: Exploring the Outer Planets

Beyond the realm of Mars, springs have also made their way to Jupiter. Launched on the 5th August of 2011 aboard the Atlas V rocket, the Juno spacecraft has travelled millions of miles to Jupiter, the largest planet in our solar system. Custom springs were used aboard this mission to perform a variety of functions, from powering the spacecraft to conducting scientific measurements.

There are over 60 custom springs aboard the Juno spacecraft, each designed to perform specific tasks. They help open the spacecraft’s solar panel doors so that the spacecraft maintains power throughout its journey. Springs also ensure the spacecraft doors remain securely latched during flying, and they assist in deploying the orbit arms once Juno reaches Jupiter, allowing the spacecraft to gather measurements of the planet’s structure.

Types of Springs Found in Space Exploration

There are several different types of springs used in space exploration; here are some of the main types:

  • Compression Springs: These springs absorb and release energy when compressed. They are used in satellite deployment systems to deploy antennas and solar panels and in space rovers for shock absorption and stability on rough terrains.
  • Torsion Springs: Torsion springs twist on an axis to provide rotational force. These springs are helpful in space applications where limited space is a concern, like mechanical latches or door hinges.
  • Tension Springs: These springs extend under tension and are used in applications handling heavy loads over long distances. In space, they are designed to withstand extreme temperatures and potential corrosion from space conditions.

As we’ve outlined, springs play a critical role in space exploration in a number of different applications. To learn more about springs in different industries, visit our blog, and for any queries about the products we supply, please contact us.

Springs play a crucial role in many aspects of daily life, but some of their most essential applications are in life-saving medical devices. From pacemakers to X-ray machines, springs are fundamental components that help ensure these devices function effectively. Whether compression springs, gas springs, or tension springs, their uses in life-saving technology are vast and indispensable.

As experienced spring manufacturers, we supply high-quality, reliable springs across a range of industries, from aerospace to manufacturing. We understand the critical importance of precision and durability in every spring we produce.

Read on to discover how our springs can contribute to life-saving innovations.

Considerations for Springs in Life-Saving Applications

Springs in life-saving applications must perform flawlessly. Not only to ensure the reliability of the device but also to safeguard the well-being of those who depend on it. Designing springs for the medical industry requires careful consideration of several key factors:

  • Spring Material: The material that a spring is constructed from must take into account the demands of the application. For instance, some devices need to withstand exposure to harsh environments, including moisture and chemicals. This means they need to be made from a corrosion-resistant material like stainless steel.
  • Spring Type: The type of spring selected is equally as important as the material, with different springs offering different benefits. For instance, compression springs are used in areas where a spring’s force is used to provide controlled movement or pressure, whereas torsion springs work best where rotational movement is required.
  • Regulations and Standards: It is vital that springs comply with necessary regulations and standards. We are both ISO 9001 and ISO14001 certified, which exemplifies our commitment to quality manufacturing processes and sustainability.

Pacemakers

The pacemaker is an important medical device that sends electrical impulses to the heart if it beats at an irregular rate, whether this is too slow, or too fast. Pacemakers are vital to the survival of many people, but did you know that springs are used to create them?

Springs are implemented in pacemakers to make sure that the leads connecting the electrical circuits to the heart do not become disconnected, otherwise known as active fixation. This is an essential component, as a dislodged or disconnected lead can lead to permanent damage to the heart. The springs found in pacemakers tend to be compression springs, a versatile and dependable form of spring that we manufacture.

Syringes

Compression springs are also commonly used in syringes, particularly in auto-injectors. These devices are designed for patients to safely and easily self-administer medication at home. The mechanism of an auto-injector is similar to that of a ballpoint pen, when not in use, the needle remains inside the syringe, and a pre-loaded spring pushes it out when the button is pressed. This ensures precise and automatic medication delivery, offering a convenient and reliable solution for patients who require injected treatments.

Ventilators

Ventilators, commonly used in hospitals, play a vital role in assisting patients with breathing. Tension springs are found in the valve mechanism of ventilators. This mechanism controls the flow of air and oxygen to and from a patient. The tension springs work to create tension which regulates the opening and closing of valves.

Compression springs are also found within ventilators, particularly in the pressure regulation system. They assist in managing the pressure of delivered air, so that it meets the set requirements of a patient’s needs. These springs need to be reliable, as they are crucial in ensuring that the pressure systems in ventilators are responsive and accurate.

Gas springs help to create flexibility in the position of certain areas of a ventilator due to their controlled and precise movement. Gas springs are found throughout hospitals, from hospital beds to adjustable wheelchairs, and are a vital tool in ensuring equipment is placed in the correct position and comfortable for both patients and healthcare workers.

Imaging Equipment

Medical imaging machines, such as X-rays, MRI, and CT scanners, are vital diagnostic tools that help healthcare professionals detect non-visible health issues. These life-saving devices rely on springs for precision, balance, and flexibility, allowing them to adjust seamlessly to patient needs.

Springs also play a crucial role in X-ray tables, enabling controlled movement for precise patient positioning. This ensures accurate imaging, which is essential for effective diagnosis and treatment.

Our Commitment to Quality and Safety

Here at European Springs, quality and safety are at the forefront of everything we do. We understand the implications of spring failure in these critical applications. That’s why we implement advanced manufacturing and quality control processes to ensure our springs are safe to be used in critical medical devices. To learn more about our processes, or to commission the production of your custom spring solution, please contact us.

Springs serve a wide variety of purposes across many industries, from aerospace to electronics. One sector where springs play a particularly vital role is healthcare. From hospital beds to life-saving medical devices, the applications of springs in the medical industry are vast and essential.

At European Springs and Pressings Ireland, we specialise in manufacturing high-quality springs designed to ensure safe, reliable, and efficient performance.

In this blog, we’ll explore how different types of springs, including compression springs, gas springs, and torsion springs, support critical medical applications. Keep reading to discover how our products help maintain the highest standards of reliability in healthcare.

Compression Springs

Compression springs are among the most commonly used springs in the medical sector, thanks to their versatility and reliability. These springs feature a helical design, enabling them to store and release mechanical energy through compression and decompression. Their simple yet effective function makes them indispensable in various healthcare applications.

One everyday example of compression springs in medicine is their use in inhalers. Here, the spring applies force to move medication from the canister into the mouthpiece, where it can be inhaled by the patient.

In surgical instruments like clamps and scissors, compression springs help maintain consistent pressure, ensuring secure tissue handling during procedures. The use of high-quality, durable springs is crucial in these tools, as precision is essential for successful surgical outcomes.

Compression springs are also integral to ventilators, where they help regulate airflow by controlling the pressure of delivered air – a critical function that supports patient breathing. Additionally, these springs are found in medical syringes, particularly within the plunger mechanism, allowing for the controlled and accurate administration of medication.

From life-saving devices to everyday medical tools, compression springs serve as a reliable and versatile component, contributing significantly to the efficiency and safety of healthcare equipment.

Gas Springs

Gas springs, otherwise known as gas struts, are springs that incorporate compressed gas into their functionality. They have a variety of applications, from vehicles to adjustable furniture, and are designed to lift, lower, and control the movement of heavy loads.

Within the healthcare industry, gas springs are used in hospital and physiotherapy beds, enabling height adjustment and back or leg elevation, helping to comfort the patient and make treatment easier for medical workers. The same functionality applies to things like drug cabinets and mobile workstations, assisting with height adjustment, angle readjustment and the control of lid opening and closing.

Gas springs are commonly found in areas of lighting or mounting within a hospital. For instance, the lighting arms that overlook patients and staff in an operating room rely on gas springs, as well as X-ray or live TV screens. This goes for outside the hospital, too, as similar kinds of lighting arms are found in the rooms of dentists and opticians. Gas springs allow these to be moved easily, ensuring that they are positioned in the ideal spot for both the patient and practitioner.

Torsion Springs

Torsion springs work by applying a twisting force rather than a compressive force. When the spring is twisted, it stores energy that is released when the spring reverts to its original position. They are also a common and versatile spring type, making them suited to a vast range of applications. For instance, medical mobilisation devices and hospital beds utilise torsion springs. They assist in smoothly raising or lowering sections of a hospital bed with minimal effort, as well as allowing the beds to lock into place once the desired position is achieved.

Torsion springs can also be found in diagnostic equipment, such as blood analysers, where they help to achieve the precise movement and handling of blood samples. They are also playing a vital role in the evolving sphere of surgical robotics and prosthetics, helping to facilitate movement in a controlled yet natural way. The spring’s torque function is able to replicate the natural bending and straightening movement of a human joint, aiding the creation of more realistic and functional prosthetic limbs.

Metal Stampings

In addition to springs, pressings and stampings have an abundance of uses in the medical sector. Metal stampings are created using a process of cutting or shaping metal sheets and can create a variety of components, from flat parts to three-dimensional shapes. When creating stampings and pressings for the medical industry, using sterile, high-quality materials is imperative for maintaining hygiene and easy cleaning. Materials like stainless steel are particularly adapted to this purpose, as they are resistant to corrosion and are a sterile type of metal.

Many common medical parts, including surgical instruments, medical device enclosures, imaging equipment and temperature probes, are made up at least in part from medical pressings and stampings. When it comes to pressings and stampings, we are equipped to handle a range of custom requests, dealing with materials in thicknesses anywhere between 0.05mm and 4mm. We are also able to construct your springs and pressings from a selection of materials, including stainless steel, ensuring that your products are surgical grade.

When it comes to the medical industry, springs and pressings must be constructed of the highest quality and materials, as the consequences of their failure are drastic. That’s why it must be a priority to select a spring manufacturer that has years of experience and high standards, like us here at European Springs and Pressings Ireland. If you would like to discuss the production of a custom product for the medical industry, please don’t hesitate to get in touch.

For those ambitious and complex engineering projects, having a well-developed design process can make all the difference when crafting a high-quality result. At European Springs and Pressings Ireland, we have fine-tuned the way we design our products to deliver reliable and customised results. 

In this blog, we’ll be breaking down the various stages of our design process and how each step is vital to a successful end result. As experienced spring manufacturers, we understand how the minor details of the design stage can influence the success of the springs and pressings we create, and that’s why we take our design process incredibly seriously. 

Why is the Design Process so Important?

The design process is not just a set of steps; it is the foundation for a product’s success. When it comes to manufacturing springs and pressings, the effectiveness of the design stage directly impacts the overall performance and reliability of the final product. Without a solid design process, engineers risk creating solutions that don’t function as intended or fail to meet the requirements of the application.  

Within this process, engineers can identify potential issues early on using prototyping and testing, allowing them to be corrected before they become costly problems. Moreover, the design process is an opportunity for the engineer and client to communicate on the project, ensuring that the final result meets the client’s expectations and requirements. A well-thought-out design process is essential for turning ideas into reality while ensuring that those ideas are practical, efficient, and durable.  

Identifying the Problem

Every engineering project begins with a clear understanding of the problem that needs to be solved. In the case of spring and pressing manufacturing, this typically means tackling a specific challenge where a new solution is required. Before starting the design process, engineers consult with clients to fully understand the issue, collect relevant data, and conduct experiments. This may also include investigating methods that others have used to tackle similar problems. This research phase ensures that we have all the information necessary to fix the problem.  

There are several factors engineers to take into consideration when designing products like springs, such as free length, solid height, number of coils, travel and load, spring ends, force capacity, and inner diameter. Additionally, they assess the environment in which the product will be used to identify potential restrictions. This may involve adapting the design to meet specific client requirements, like applying electroplating or powder coating treatments, to help make your product last longer in its application.  

Prototyping

Once the design concept is established, the prototyping phase allows engineers to refine their ideas and learn from any mistakes before the product enters the real world. Prototypes are functional models that undergo testing to assess their performance in the intended environment. This is when the real learning takes place, because all the team will be taking notes about the test and the performance of a prototype in its desired environment. For example, if the product will be used in a marine setting, non-corrosive materials may be considered. The prototyping stage can often be extensive as engineers conduct design improvements and refinements and can be a great way to showcase any problems within the initial design. 

At European Springs and Pressings Ireland, our CAD CAM software and systems allow us to create a range of prototype ideas so that you can see what will work best for your given application. Prototypes can be cut individually using precision lasers or put into full production following the assembly of samples. Before we put any product into manufacturing, our engineers test and trial the product thoroughly to ensure that the final result is the best it can possibly be. Once we have validated your design, our tool room is used to design and build any production tooling that is needed.  Prototyping can be done both virtually and physically and can help to take a concept from idea generation to a perfect final result. Virtual prototyping includes the building of a virtual model, which is a quick way to test any flaws in the design before they are developed into a physical prototype. This is also useful for gaining client feedback on a given product and allows engineers to make any changes. 

Expert Design with European Springs and Pressings Ireland

A strong design process can elevate an ordinary project into an exceptional one. At European Springs and Pressings Ireland, we are committed to collaboration and innovation in every step of the design process. By embracing the latest manufacturing techniques and continuously improving our design practices, we ensure that every product we create meets the highest standards of quality. 

If you have any questions about our design process or products, please contact our team. We are ready to assist you with your inquiry and provide solutions tailored to your specific needs.  

There are many essential components within a pickup truck’s brake system, including brake pads, callipers, and rotors. Due to their higher load capacity than regular cars, these braking systems need to be able to withstand significant weight and perform well under pressure.  

Spring clips are a crucial part of pickup truck brake systems. They help to reduce noise and drag, which can extend the lifespan and overall reliability of your vehicle. At European Springs and Pressings, we are experts in designing spring clips that are perfectly suited to your requirements and can manufacture a range of spring clips for various applications.  

In this blog, we’ll explore how spring clips are used in the brake systems of pickup trucks, including real-world examples and an exploration of the different types of spring clips we manufacture.   

Where are Spring Clips in Pickup Trucks?

Within braking systems, spring clips can be found at the end of brake pads. They are essential in brakes, as they apply tension on the brake pad to keep it off the surface of the brake rotor when the brakes aren’t in use. This reduces unwanted noise and helps to maintain consistent contact between the pads and the rotors.  

These clips are continuously developed for applications in industries such as the automotive industry, which ensures that vehicles are manufactured with increased safety and can be used alongside disc springs. With brakes being a highly important component in vehicles, it’s vital to have quality springs that ensure the integrity of other vehicle parts. 

How Spring Clips Work in Pickup Truck Systems

In pickup trucks, the braking system is put under a lot of stress due to the size and weight of the vehicle, as well as the frequent towing and heavy payloads that many trucks are required to handle. Spring clips are strategically placed at the ends of the brake pads or on the bracket assembly to ensure the pads remain securely positioned and function properly during braking. There are a few key ways that spring clips contribute to the brake system: 

  • Keeping the Brake Pads in Place: Spring clips prevent the brake pads from shifting too much within the calliper. When the pads are in the correct position, they provide maximum contact with the rotor so that the vehicle stops as quickly as possible. This is important because consistent movement can lead to uneven wear and unsafe breaking.  
  • Reducing Noise and Vibration: When the brake pads move too much or make contact with parts they shouldn’t, it can cause unnecessary noise. Spring clips apply a small amount of tension to the brake pads, helping to prevent this unwanted noise and vibration.  
  • Preventing Wear: Brake pads are subject to friction with every use. The spring clips work to maintain consistent positioning so that the pads wear evenly across the surface. Without spring clips, the brake pads may wear unevenly, which results in the need for frequent replacement and higher maintenance costs.  

The Fourth Generation of Dodge Ram Brakes

An example of spring clips being used in pickup truck braking systems can be seen in the fourth generation of Dodge Ram Brakes, which come in both heavy-duty and light-duty packages. For the light-duty package, spring clips are placed at the ends of the brake pads, helping to reduce noise and drag by keeping the pads properly aligned and preventing unnecessary movement. This results in smoother braking and less friction.  

In the heavy-duty package, abutment clips are used, which perform a similar function by maintaining tension on the brake pads and preventing them from contacting the rotor when not in use. These spring clips not only reduce noise but help extend brake pad life and keep the brakes cooler during use, which are key for both everyday driving and towing tasks.  

Spring Clips at European Springs and Pressings

At European Springs and Pressings, we understand the importance of high-quality spring components in automotive systems. Our team of experts continues to innovate and design springs that meet the demands of different applications, including those in the automotive industry. If you’re interested in learning more about the spring clips we offer, please feel free to contact us.  

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