Category: Engineering

In the fast-paced world of electronics and technology, the role of wire forms cannot be overstated. These seemingly humble components play a vital role in various applications, ensuring the smooth functioning of electronic devices and systems.

Wire forms are the unsung heroes behind the scenes, from circuit board assembly to wearable technology and beyond. Read on to learn more about the importance of the reliably high-quality wire form manufacturing we do here at European Springs Ireland.

Are Springs also Wire Forms?

Wire forms are indeed a form of spring, but it is important to note that not all wire forms are classified as springs. While springs primarily serve as energy-storing components, other wire forms serve different purposes and contribute to the overall functionality of a wide range of products.

Wire forms that are not springs are formed or shaped to fulfil a specific role. They are often customised to fit specific applications and may not exhibit the same degree of elasticity or energy storage as traditional springs. Instead, they provide structural support or facilitate connections in electronic or other applications.

Types of Wire Forms Used in Electronic Applications

The electronics industry heavily relies on wire forms to create components essential for numerous applications. While wire forms come in various shapes and sizes, several types are commonly used in electronic applications. Here are some examples of how they are utilised.

• Compression springs are one of the electronics industry’s most widely used types of wire forms. Compression springs maintain pressure between two components or provide cushioning or support. For example, compression springs are used in battery contacts, circuit breakers, and switches.
• Torsion springs work by twisting or torsion instead of compression or extension and are found in relays, switches, and connectors.
• Custom wire forms may have complex shapes and configurations and often have features such as hooks, loops, or other specific geometries. An example of bespoke wire forms in the electronics industry may be contact springs for a sensor or a particular bracket for connections or mounting other components.

Wire Forms in Circuit Board Assembly and Interconnections

Wire forms play a vital role in circuit board assembly and interconnections, ensuring the proper functioning of electronic devices. For example, they’re used as connectors to establish electrical connections between different components within a circuit board. These connectors allow for transmitting signals, power, and data between the various parts of the circuit. Wire forms used in circuit board assembly can be clips, soldered wires, or tightly wound coils.

Wire Forms in Connectors and Cable Assemblies

In cable assemblies, wire forms provide strain relief, which helps to protect the connection points from excessive tension and bending. They enhance the longevity of cables by preventing wire fatigue and damage due to repeated movement or stress. Wire forms also aid in cable management by keeping the cables organised and reducing the risk of tangling.

Wire Forms in Antennas and Wireless Communication Systems

Wire forms in antennas function by converting electrical energy into electromagnetic waves and vice versa. They enable the transmission and reception of signals, allowing for reliable wireless communication. This hardware ensures efficient propagation and reception of signals, leading to improved signal strength and coverage.

Wire Forms in Display Technologies

Wire forms ensure seamless communication between the display panel and the integrated circuitry, allowing for the control and manipulation of individual pixels. They enable the delivery of electrical signals necessary for pixel activation, colour control, and backlighting. Wire forms also contribute to the display’s overall mechanical stability and durability, preventing disconnections or interruptions in the electrical pathways.

Wire Forms in Wearable Technology and Internet of Things (IoT) Devices

In IoT devices, wire forms support sensors, connectors, and antennas, allowing for seamless integration and functionality. They form the backbone of the device’s electrical connections, facilitating data transfer and communication within the IoT ecosystem. The flexibility and customisation options of wire forms make them ideal for the compact and intricate designs of wearable technology and IoT devices, ensuring efficient operation in diverse situations.

Wire Forms in Computer Keyboards

Computer keyboards rely on spring wire forms to facilitate the tactile response and feedback required by users—specifically, a type of spring known as the buckling spring is used. A buckling spring is a coil spring wire form installed underneath each keycap on the keyboard. When a key is pressed, the buckling spring is compressed in a specifically buckled way, which triggers a hammer buckle switch below it, resulting in activated input.

Benefits Wire Forms Provide Electronic Applications

Wire forms offer numerous benefits in the electronics and technology industries, making them essential to many products, for example:

• Reliability: Wire forms withstand external forces and wear and tear, making them highly reliable. They contribute to the longevity and durability of products where implemented.
• Mechanical Stability and Support: Wire forms are internal structures that provide mechanical stability and support to various electronic components. They prevent mechanical failure and ensure that products function optimally throughout their lifespan.
• Improved Electrical Conductivity: Many wire forms are made from highly conductive metals such as copper, facilitating effective electrical conductivity. This means they can support the high-performance electronic components and devices required for various applications.
• Flexibility and Customisation Options: Wire forms suit different electronic applications and are highly adaptable. Our wire form manufacturers use wire forms to create a variety of components with customised shapes, sizes, and materials.

UK Leading Electronic Wire Form Manufacturer

So, as you can see, wire forms play crucial roles in almost every electronic application imaginable. We have manufactured the highest quality wire forms for all the previously mentioned applications and more, thanks to the expertise of our engineers. Contact us today to discover the versatility and adaptability of these components with our in-house wire form manufacturers.

Guaranteeing that manufacturing has plenty of up-and-coming employees of the future is still one of the biggest challenges the industry faces today. With the skills gap in manufacturing still suffering from the after-effects of the pandemic, there can be no let-up in the pursuit of attracting talent to the manufacturing industry.

At European Springs Ireland, we’re incredibly passionate about inspiring future generations and encouraging young people into STEM careers. This drive has led us to build a fantastic apprenticeship program to provide young people with the skills and experience to propel them into fruitful careers.

So, today we’re exploring this by looking into ways businesses in the manufacturing sector can continue to attract some of the best manufacturing talent from around the country.

Hold Online Workshops and Presentations Aimed at Young People

Putting on manufacturing-related workshops that could pull in some of the top manufacturing students from around the country offers your business the perfect opportunity to begin attracting the younger generation. Events like these offer an excellent platform to showcase your company’s expertise and show young people hoping to enter the industry that you are passionate and serious about helping young people learn their trade.

There’s no doubt that by holding an hour-long seminar or two-hour workshop online, you will increase your stock as a manufacturing business while engaging the next generation of engineers. You can rest assured that the next time you come to recruit for entry-level positions, you will receive many applications from those who attended your seminar.

We can’t overstate the importance of having a good relationship between yourself and the next generation of workers. It’s essential to attract the very best talent that is available, so taking the time to engage with them in such a tough time will go a long way to helping solidify this relationship.

Hold an Open Day

If you’re looking to employ young people within your manufacturing business, but are struggling to find the right candidates, then we recommend holding an open day.

To maximise the chances of finding your ideal candidate, it could be worth getting in touch with universities within close proximity of your premises and letting them know you’ll be holding a guided tour of your facilities. Of course, it’s worth mentioning that the end goal of this day is to have some of the attendees apply for a role within the business if they have a relevant skillset.

Alternatively, you could hold an online ‘open day’ for those who cannot physically attend. This could comprise one of your staff members using a mobile phone to stream a guided tour of your facility while giving some insight into the roles available within your company.

This may be seen as a bit of an ‘out there’ idea, but it would certainly break the mould and appeal to younger people. Giving potential candidates a chance to see your manufacturing processes and gain insights into how they may be working will entice and excite any young person looking to gain employment in the sector.

Leveraging Technology and Innovation

As a leading spring manufacturer, we understand that leveraging technology and innovation can significantly help manufacturers attract young people to their business. Manufacturers can enhance efficiency and productivity by adopting advanced technologies such as automation, robotics, and artificial intelligence and create a high-tech work environment. Younger generations are often drawn to industries that embrace cutting-edge technologies and offer efficient processes, so integrating new technology provides ample opportunities for young people to delve in and be inspired.

In addition, working in an industry that embraces technology and innovation can help young people stay relevant in a rapidly evolving job market. Manufacturing companies that employ eco-friendly technologies and promote sustainability initiatives attract young talent who are passionate about environmental issues. By highlighting these aspects, manufacturers can create an appealing and forward-thinking environment that resonates with young people, making the manufacturing industry more attractive to the younger generation as they seek growth opportunities and contribute to a greener future.

Here at European Springs & Pressings Ireland, we take great pride in being forward-thinking spring manufacturers. That’s why we continually invest in our staff and equipment to guarantee that we are always at the forefront of our industry. We understand just how important it is to give our young engineers the best possible start to their careers, and we hope that many other businesses in the industry continue to support their growth for the betterment of the sector as a whole.

If you’re interested in our apprenticeships, please don’t hesitate to get in touch, and a member of our team will be more than happy to guide you in the right direction. Alternatively, please stay updated with industry news about the future of manufacturing apprenticeships so you can stay informed about current affairs and put yourself in the best possible position for a great start to your career.

Springs are crucial in countless industries, offering essential functionality and support in diverse applications. While standard spring elements may suffice for many common needs, certain industries require bespoke solutions to meet their unique requirements and demanding operating conditions.

So, today we’re delving into the world of bespoke springs and exploring which industries benefit most from custom-designed spring solutions. European Springs Ireland, leading bespoke spring manufacturer, understands the importance of tailored approaches to meet industry-specific challenges. And with our expertise and extensive range of custom spring capabilities, we are the ideal partner to navigate the diverse needs of various sectors.

Let’s explore the industries we work with and the various sectors that benefit from our expertise, precision, and attention to detail.

The Industries We Work with at European Springs Ireland

At European Springs Ireland, we are lucky enough to work in a fascinating, fast-paced, and diverse industry. Our specialised work means we can collaborate with businesses and individuals from an extensive range of sectors. Despite coming from a spectrum of backgrounds, our customers have one thing in common: a need for high-quality, bespoke springs.

Our vast experience, and our dedicated team of designers, manufacturers, and quality checkers work hard to ensure each customer gets exactly what they need for their desired application.

Automotive

The automotive industry greatly benefits from bespoke springs due to their unique and demanding requirements, and these custom-designed springs play a vital role in various automotive applications, ensuring optimal performance, safety, and efficiency.

Bespoke springs in the automotive industry are tailored to specific needs, such as suspension systems, engine components, braking systems, and seat mechanisms. These custom springs are designed to withstand varying loads, provide precise force control, and offer superior durability and reliability.

For example, custom torsion springs are in various automotive components, such as hinges, latches, and trunk lid mechanisms. These springs store and release rotational energy, providing torque for smooth and controlled movement. Standard torsion springs are often perfectly acceptable, but those in the automotive industry sometimes require something incredibly unique and precise, which is when we step in.

Defence

Bespoke springs provide tailored solutions to meet the demanding needs of defence applications such as weapons systems, armoured vehicles, communication equipment, aircraft, and more. These custom springs are designed to withstand extreme conditions, including high shock, vibration, and temperature variations.

Because of this, standard spring elements are not usually enough. Working with the defence industry involved a lot of conversations, collaborations, and communication to ensure that the details are accurate and they receive a product perfect for their application. For example, our custom springs can be designed to handle heavy loads, provide precise force control, resist corrosion, and endure harsh environments or whatever else is required.

Medical

The need for bespoke springs in the medical industry arises due to the unique and demanding nature of medical applications. Customisation ensures the springs are optimised for specific requirements, such as size, shape, material, and performance characteristics. This level of customisation ensures the springs are tailored to the intended use, enhancing the overall effectiveness, precision, and safety of medical devices.

For example, bespoke compression springs are widely used in medical devices and equipment where they provide resistance to compression forces. They are often used in applications such as implantable devices, surgical instruments, and drug delivery systems.

Lighting

Interestingly, bespoke and custom springs play a significant role in the lighting industry due to the unique requirements and diverse applications within this sector. Our specialised springs are designed and manufactured to meet the specific needs of lighting fixtures and systems, such as:

• Connecting and securing bulbs
• Supporting reflectors or lenses
• Facilitating adjustable features like swivelling or tilting mechanisms
• Enabling smooth operation of switches and dimmers

One of the key reasons bespoke springs are used in the lighting industry is the need for precise and reliable positioning of components. These springs provide the necessary tension, compression, or torsion forces to ensure proper alignment and movement of various parts within lighting fixtures.

Oil and Gas

The harsh environments and extreme operating conditions in oil and gas applications necessitate custom-designed springs to ensure reliability, durability, and safety.

For example, bespoke springs also play a vital role in valve and actuation systems within oil and gas equipment. They provide precise control and movement, allowing for the efficient operation of valves, safety systems, and other critical components. These springs are designed to meet specific force requirements, ensuring optimal performance and functionality.

Because of this, there are often many trials and testing with the custom springs we design for the oil and gas industry. The springs must withstand high pressure and temperature variations, so we usually design and create prototypes for testing before we begin with the final order. This ensures the customer gets a product that will stand the test of time and perform well in its application.

So, no matter the industry you work in, the team are European Springs Ireland is sure to be able to help. To enquire about a bespoke spring order, please contact us today; we can’t wait to hear from you and get started on your project.

There’s a lot to consider when bringing your spring and pressing designs to life, and it can be overwhelming if you’re not too familiar with the design process. Translating your vision and needs into a tangible product can be daunting without the proper tools and techniques, which is why prototyping exists.

Prototyping is an invaluable resource for designers looking to refine their ideas and create a successful product. So, from choosing the right materials and tools to refining your designs, we will guide you through the prototyping process and show you how to create a functional and aesthetically pleasing product with the help of our expert designers and engineers. Let’s dive in and discover the power of prototyping in creating exceptional spring, pressing, and wireform designs.

What Is Prototyping?

Prototyping is the process of creating a preliminary version or model of a product, design, or system to test and refine its functionality and design. It can be used in a wide range of industries, from product design and engineering to software development and user experience design.

The purpose of prototyping is to identify any flaws, errors, or limitations in the design and functionality of a product or system and to make necessary adjustments before it is finalised and launched. The prototyping process can involve creating physical models, 3D printed objects, wireframes, or even virtual simulations. Through prototyping, designers and developers can refine and improve their ideas, resulting in a more polished and successful final product.

The Importance of Prototyping

In terms of design, prototyping plays a crucial role as it allows our engineers and designers to test and refine their ideas before moving to production. For example, springs are used in various industries, including automotive, aerospace, medical, and consumer electronics, among many others, so, rapidly prototyping and testing new designs can help companies like ourselves reduce time to market, improve product quality, and lower development costs. Here are some of the key benefits of prototyping in both the design of springs, pressings, and wireforms:

• Testing Functionality. Prototyping allows designers to test the functionality of a spring design and identify any potential issues or areas of improvement. This can help ensure the final product meets the necessary performance requirements and can operate reliably over its expected lifespan.
• Material Selection. Prototyping allows designers to test different materials and evaluate their performance under different conditions, such as temperature and load. For example, pressings involve shaping a flat sheet of material into a desired form through processes like stamping or deep drawing. The material’s formability determines how easily it can be shaped without cracking or tearing. Some materials, such as aluminum or certain grades of steel, exhibit excellent formability, making them suitable for complex pressings and the prototype can help determine this.
• Customisation. The prototyping process can be used to create bespoke springs tailored to specific applications or customer needs, such as ours here at European Springs Ireland.
• Cost Optimisation. Prototyping can also help identify opportunities to optimise a wireform design for cost reduction, for example. By reducing the amount of material used or simplifying the manufacturing process, we can create a cost-effective wireform that meets your needs.

Overall, prototyping is a critical step in the design process that enables engineers and designers to refine their designs and ensure that the final product meets the necessary performance requirements. By testing different materials, shapes, and sizes, we can create custom springs, pressings, or wireforms optimised for their specific application and reduce the risk of expensive design errors or manufacturing defects.

Types of Prototypes

Several types of prototypes can be used in spring, pressing, and wirefoem design, depending on the specific application and requirements; let’s take a look.

• Proof of concept prototype. This is used to test the basic functionality of the design. It may be made from simple, low-cost material like plastic or wire and is used to ensure the spring, pressing, or wireform will function as intended.
• Functional prototype. This is used to test the performance of the design under real-world conditions and is often made from more durable materials like metal. It may be tested for strength, durability, and fatigue resistance.
• Appearance prototype. This type of prototype is used to test the aesthetic qualities of the compression spring design, for example, such as its shape, colour, and finish. It may be made from various materials, including plastic, metal, or even 3D printed materials, and is used to evaluate the design’s visual appeal.
• Engineering prototype. These prototypes are used to test the design’s manufacturability and ease of assembly. Typically, it is made from the same materials used in the final product to ensure that the design can be efficiently manufactured and assembled. For example, a bespoke metal pressing will be manufactured from the desired metal,
• Pre-production prototype. This is used to test the design’s performance in large-scale production runs. It is made using the same manufacturing processes used for the final product and is used to identify any potential manufacturing issues that may arise during production.

The kind of prototype utilised in the design will vary based on the distinct needs of the application and the phase of the process, and our expert designers and manufacturers will use the appropriate method depending on your needs.

Prototyping at European Springs Ireland

Our Engineering and Production facility can provide quick prototyping services, utilising techniques like Laser Cut/Chemically Etched Blanks or simple Blanking Tools. For forming, we use standard tooling that offers a cost-effective solution for situations where the final part design has not yet been established or for low-volume parts where tooling investment is unnecessary.

Whether you need a one-off prototype or low-volume parts for testing purposes, we are fully equipped to meet your requirements.

Please don’t hesitate to contact our team to find out more about what we can offer you so you can get the most out of your springs, pressings, or wireforms.