Custom Spring Production: A Complete Guide from Design to Delivery

Jun 05, 2025

Custom Spring Production: A Complete Guide from Design to Delivery

Looking for a reliable custom spring manufacturer to bring your unique product designs to life? Whether you're in automotive, aerospace, medical, or industrial sectors, custom precision springs are critical components that require attention to detail and expertise. In this guide, we’ll take you through the various types of springs, what to consider during their design, the spring manufacturing process, applications, and why choosing a quality-certified ISO 9001 spring manufacturer like Janee Machining can make all the difference.

What is Spring？

Have you ever stopped to think about how custom springs are made? These powerful components are the hidden force behind many of today’s most advanced machines. From your car’s suspension to the tiny switches inside your favorite electronic device, mechanical springs are everywhere—and understanding how they’re manufactured can help you appreciate their incredible versatility and select the right type for your application. At its core, a spring is a specially formed piece of wire designed to store and release energy by deforming under load. But don’t let the simplicity fool you—behind every high-performance compression spring, torsion spring, or extension spring is a precise manufacturing process and thoughtful engineering tailored to each use. You’ll find stainless steel springs in sterile medical tools, heavy-duty springs in industrial presses, and precision micro-springs in sensitive electronic systems.

1. Types of Springs & Their Applications

Compression Spring

A compression spring is a coiled wire designed to resist a force when compressed. When you push down on it, the spring gets shorter and stores energy. As soon as you release the pressure, it bounces back to its original shape. The tighter you press, the harder it pushes back.
Applications:

Ballpoint Pens: When you click the top, you compress the spring, which then pushes the pen tip out and keeps it extended until you click again.
Car Suspension Systems: Compression springs absorb shocks from bumps and potholes, giving you a smoother ride
Medical Devices: They help maintain consistent pressure or allow gentle, precise movements inside devices like syringes and surgical instruments.
Mattresses: Springs inside support your weight evenly for comfort and durability.

Why it’s Prefer:
It pushes back when compressed, making it perfect for absorbing shock or returning parts to their original position.

Custom Compression Spring

Custom Extension Spring

2. Extension Spring
An extension spring works the opposite of a compression spring. Instead of being squeezed, it’s stretched apart. It stores energy as it extends and tries to pull back to its original, tighter position. It usually has hooks or loops on both ends to connect different parts.
Applications (explained):

Garage Doors: Extension springs help lift the heavy door by pulling it upward when you open it.
Trampolines: The springs stretch when you jump, storing energy, then release it to bounce you back up.
Toys (like pull-back cars): When you pull the toy back, you stretch the spring. Letting go makes it zoom forward.
Farm Equipment: They keep tension in mechanical linkages, ensuring parts stay aligned even during rough use.

Why it’s Prefer:
It helps pull things back together and keeps tension steady.

3. Torsion Spring
A custom torsion spring stores energy when it’s twisted rather than pulled or squeezed. Picture turning a door handle: as you rotate it, the spring twists, building force that either returns the handle to its resting position or controls its motion.
Applications:

Clothespins: When you pinch open a clothespin, the torsion spring twists. Letting go causes it to clamp tightly onto clothes.
Car Trunks and Hoods: Torsion bars help lift the heavy trunk lid easily and hold it open.
Mouse Traps: The spring stores a lot of energy when you set it, ready to snap shut quickly when triggered.
Self-closing Hinges: Doors automatically return to closed position thanks to the twisting motion of torsion springs inside the hinges.

Why it’s Prefer:
It gives controlled rotational force — perfect for flipping, turning, and holding angles.

Custom Torsion Spring

Custom Constant Force Spring

4. Constant Force Spring
Unlike regular springs that get harder to pull the more you stretch them, a constant force spring gives you steady, consistent resistance across its entire movement. It’s usually a flat strip of metal coiled tightly — as you pull it out, it unwinds and offers a smooth, even pull.
Applications:

Seat Belt Retractors: When you pull out a seatbelt, it feels smooth and even because of the constant force spring inside the retractor.
Tape Measures: As you pull out the measuring tape, it comes out easily, and the spring automatically winds it back smoothly when you’re done.
Window Shades: You pull down the shade, and the spring inside controls its motion so it doesn’t snap up or fall too fast.
Brush Motors: Constant force springs press brushes against the motor's rotating part, ensuring consistent electrical contact.

Why it’s Prefer:
It provides a smooth, reliable pulling force without getting weaker the more it’s pulled.

5. Conical Spring
A conical spring is shaped like a cone — wider at one end and narrower at the other. This design allows the coils to nest inside each other when compressed, saving a lot of space compared to a regular spring.
Applications:

Battery Holders: Those little springs inside remote controls or flashlights that press the battery into place are often conical.
Heavy Equipment: Machines that require compact, strong springs that don't buckle under pressure use conical springs.
Electrical Contacts: They help maintain consistent pressure even as things vibrate or move, keeping connections stable.

Why it’s Prefer:
It can compress into a really small space without buckling, making it super space-efficient!

Custom Conical Spring

Custom Flat Spring

6. Flat Spring
A flat spring isn't coiled — it’s a thin, flat piece of metal that bends under force and then returns to its shape when the force is removed. Flat springs can come in many shapes — sometimes simple strips, sometimes more complex stamped designs.
Applications:

Leaf Springs (in trucks): These heavy-duty flat springs support the truck’s weight and absorb shock when driving over rough roads.
Clocks and Watches: Flat coil springs inside keep the gears turning at a consistent pace.
Electrical Switches: Flat springs help snap the contacts open or closed quickly, ensuring clean and fast electrical connections.
Clips and Clamps: Binder clips, hair clips, and other clamps often use flat spring materials for a strong yet flexible grip.

Why it’s Prefer:
It’s simple but powerful — offering reliable force in a compact design.

7. Custom Shaped Spring
Sometimes standard spring shapes don’t fit. That’s when a custom-shaped spring comes into play — it could be wavy, square, zigzag, spiral, or anything engineers dream up! Our custom springs are tailored to your specific force, space, or motion needs.
Applications:

Medical Devices: Our custom springs fit into small, complex tools like surgical robots or drug delivery systems.
Aerospace: Planes, satellites, and rockets use custom springs to meet extreme weight, temperature, and force requirements.
Robotics: Our unique springs help moving parts act precisely and reliably without bulky mechanisms.
Manufacturing Equipment: In assembly lines, our custom springs can apply just the right amount of force to keep machines running smoothly and safely.

Why it’s Prefer:
When regular springs can’t do the job, custom springs step in with personalized strength, flexibility, and design.

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What Wire Diameters Can Be Handled for Springs?

When making springs, wire diameter (the thickness of the wire) is super important because it affects the spring’s strength, flexibility, and performance. Common range of wire diameters that can be handled depends mostly on the equipment and the type of spring being made.

140x140

Spring Type	Common Wire Diameter Range
Compression Springs	0.1 mm to 20 mm (sometimes up to 50 mm for special heavy-duty springs)
Extension Springs	0.2 mm to 10 mm
Torsion Springs	0.2 mm to 12 mm
Constant Force Springs	0.05 mm to 1 mm (thin strip material)
Conical Springs	0.3 mm to 10 mm
Flat Springs	0.05 mm to several mm thick and several cm wide
Custom Shaped Springs	Depends — typically 0.1 mm to 12 mm, but varies a lot depending on the design

Janee CNC Wire Bending Machines Capabilities

140x140

Machine Type	Wire Diameter Range
3-Axis Multifunctional CNC Machine	0.1 mm – 1.5 mm
3-Axis Multifunctional CNC Machine	1.5 mm – 2.5 mm
4-Axis Multifunctional CNC Machine	2.5 mm – 5.0 mm
5-Axis Multifunctional CNC Machine	3.0 mm – 6.0 mm
12-Axis Multifunctional CNC Machine	5.0 mm – 12.0 mm

How Springs Are Made: Spring Manufacturing Process

Creating high-performance springs involves multiple precision steps:

Design & Prototyping: CAD modeling and FEA simulations help optimize performance. We offer spring prototyping services to validate your concept before mass production.
Material Selection: Options include music wire, phosphor bronze, stainless steel, Inconel, etc., depending on your application.
Coiling: CNC spring-forming machine coils wires with precise control over pitch, diameter, and shape.
Heat Treatment: Enhances tensile strength and fatigue resistance.
Grinding: Ends of compression springs may be ground flat for stability.
Surface Treatment: Options like shot peening, passivation, electroplating, or powder coating improve durability and corrosion resistance.
Quality Inspection: Using load testers, calipers, and microscopes, each spring is checked for dimensional accuracy and compliance.

As a trusted ISO 9001 spring manufacturer, we ensure every spring goes through rigorous quality checks before delivery.

Materials Used in Custom Spring Manufacturing

Springs can be made from a variety of materials depending on the application’s strength, flexibility, corrosion resistance, and temperature requirements.
1. Beryllium Copper Alloy
Beryllium copper alloy combines high strength, excellent conductivity, and resistance to creep. Its superior formability makes it ideal for manufacturing intricate spring components used in precision devices such as musical instruments, measuring tools, and ammunition.
2. Steel Alloys
Steel remains the most widely used material for spring production due to its high tensile strength, fatigue resistance, and versatility. Alloying elements can be added to enhance performance in specific conditions, making steel springs suitable for a broad range of industrial and mechanical applications.
3. Stainless Steel
Stainless steel springs are perfect for situations where resistance to rust and corrosion is important, like in medical equipment or outdoor tools. They’re strong but cost a bit more than regular steel.
4. Brass
Brass springs are known for being great conductors of electricity and are resistant to corrosion. While they aren’t as strong as steel, they work well for low-stress tasks, especially in electrical systems.
5. Copper
Copper springs are mainly used in electrical settings because they conduct electricity well. They're not typically used for heavy-duty mechanical springs, but can be useful in specific applications like electrical connectors.
6. Titanium
Titanium springs are super strong, lightweight, and resistant to corrosion, making them ideal for high-performance uses like in the aerospace or medical fields. However, they tend to be more expensive.

Causes and Solutions for Failure of Various Types of Springs

1. Fatigue Failure

Cause: Over time, springs experience repeated stress, which can lead to fatigue failure. This often happens when the spring is used for longer than its expected lifespan or under higher loads than it was designed for.
Solution: To prevent fatigue failure, make sure the spring is used within its designed load limits. Regular maintenance and inspection can also help spot any signs of wear before it leads to failure.

2. Corrosion

Cause: Springs exposed to moisture, chemicals, or extreme environments (like saltwater or acidic conditions) can corrode, weakening the material.

Solution: Using corrosion-resistant materials like stainless steel or applying protective coatings can prevent corrosion. For springs used in harsh environments, regular cleaning and maintenance are also essential.

3. Overloading

Cause: When a spring is subjected to a load heavier than its maximum capacity, it can lead to stretch, deform, or even break.

Solution: Always ensure that the spring is properly sized for the application. Double-check load requirements and choose the right type of spring for the job to avoid overloading.

4. Improper Installation

Cause: Installing a spring incorrectly—such as bending it too much, overstretching it, or placing it in the wrong position—can lead to premature failure.

Solution: Ensure that the spring is installed according to the manufacturer’s instructions. Proper alignment and avoiding sharp bends will help extend the spring’s lifespan.

5. Environmental Conditions

Cause: Extreme temperatures, such as very hot or very cold environments, can change the properties of a spring, leading to brittleness or softening.

Solution: For extreme conditions, use springs made from materials designed to handle temperature fluctuations, like titanium or specially coated alloys.

6. Improper Material Selection

Cause: Using the wrong material for the spring’s intended application can lead to failure. For example, using a material that’s too soft for heavy loads or too brittle for dynamic use can cause the spring to break prematurely.
Solution:Choose the right material based on the spring's function. Consider factors like load capacity, environmental conditions, and whether the spring will be used for high-stress or dynamic applications.

Why Choose Janee Precision for your Custom Spring Production?

Looking to create on-demand products that incorporate springs? JANEE Precision offers a comprehensive, one-stop solution—from sourcing the exact springs you need, to precision manufacturing, seamless assembly, and delivery in as little as 3 days. And if your project goes beyond just springs, JANEE Precision is your trusted partner for all custom manufacturing requirements.
From CNC machining and injection molding to sheet metal fabrication, we provide high-quality, fast-turnaround solutions tailored to your specifications. When your designs demand more than the ordinary, count on JANEE Precision Hardware for custom reliable, expert-driven spring production.
Whether you need short runs for testing or full-scale production, we’re your go-to heavy-duty springs manufacturer in the USA, China, and worldwide. We bring your spring ideas to life with fast lead times, expert design support, and customized finishes. Our custom spring offer…

Match your product’s exact size and shape
Handle just the right amount of pressure
Special coatings for corrosion or heat resistance
Last longer and perform better

Ready to get started on your next custom spring project? Contact Janee Machining today to request a quote or speak with one of our engineering specialists. We’re here to help you prototype, produce, and perfect your next innovation.

Final Thoughts

Custom spring design and manufacturing isn’t one-size-fits-all. It takes precision, quality materials, and industry experience. As your dedicated precision springs supplier, Janee Machining is here to turn your designs into durable, performance-driven products.
Still have questions? Don’t hesitate to reach out or browse our site for more details on custom CNC machining, prototyping services, and beyond.

FAQs

1: What materials can I choose for custom springs?
A: We offer music wire, stainless steel, phosphor bronze, Inconel, titanium, and more, depending on the mechanical, electrical, and corrosion requirements of your application.
2: What’s the typical lead time for custom spring production?
A: Standard lead times range from 2 to 4 weeks, but expedited delivery is available for urgent projects.
3: What surface finishes are available?
A: We provide black oxide coating, electroplating, passivation, beadblasting, powder coating, shot peening, and custom finishes like DLC for functional and cosmetic performance.
4: Do you offer prototyping services?
A: Yes! Our spring prototyping service ensures your spring design is fully tested and validated before moving to full production.
5: Can you manufacture springs for specific industries like automotive or aerospace?
A: Absolutely. We are a recognized automotive springs supplier and work with aerospace, medical, and industrial partners to develop application-specific solutions.

Custom Spring Production: A Complete Guide from Design to Delivery

Custom Spring Production: A Complete Guide from Design to Delivery