Precision in Spring Manufacturing

A compression spring either performs exactly as intended, or it doesn’t. There is no middle ground. A few thousandths of an inch can decide whether a hydraulic valve operates smoothly or seizes under pressure. That’s why at AWP, precision is the standard that guides every coil, grind, and load test.

Read on to see why accuracy drives performance, what happens when tolerances slip, and how AWP delivers ground compression springs that hold up under the toughest demands.

Why Precision Matters

Springs work behind the scenes, but their impact is front and center. A poorly made spring can throw an entire system out of balance, causing downtime, product failures, or worse. In equipment that moves tons of material, keeps agricultural machinery running through the season, or controls critical hydraulic valves, precision is non-negotiable.

Every spring must hit its target load, return to its free length, and repeat the cycle thousands – sometimes millions – of times without drifting from spec. Tight tolerances improve performance and keep operators safe and equipment reliable.

How Precision Is Built In

Materials That Meet the Mark

Precision starts with wire. Every coil we buy comes certified to the latest ASTM specifications and includes full lot traceability back to the mill. That means no guesswork on material chemistry or consistency, only documented quality from the start.

CNC Coiling Without Compromise

Our Simplex-Rapid CNC dual-point coilers handle wire diameters from 0.008 to 0.200 inches. Each spring is digitally measured for free length before cutoff. Parts that drift outside tolerance don’t make it past the chute; they’re removed and recycled on the spot. High-volume production doesn’t mean trading accuracy for speed.

Grinding That Defines the Standard

Flat ends equal stable load transfer. AWP has produced more than 500 million ground compression springs, and grinding is the first thing you notice when you walk into our plant. CNC and mechanical grinders, along with custom fixtures, hold springs straight while abrasive wheels do the work. The result: square ends, repeatable free length, and reliable performance every time.

Presetting That Locks in Performance

Springs lose load if they’re not stabilized. That’s why presetting happens after coiling and stress relief but before final grinding. Compressing the spring to a defined height in this stage sets the load curve and reduces relaxation over time. Our 5-axis robotic presetting system repeats that process across thousands of parts with no drop in consistency.

Inspection at Every Step

At AWP, dimensional testing with micrometers, calipers, and optical comparators confirms every detail of geometry, while computerized force testers verify that each spring delivers the specified load. Video microscopes are used to catch visual imperfections that might otherwise go unnoticed, and statistical process control tracks variation in real time to keep production on target. Every spring leaves our floor validated – never assumed ready.

What Happens When Precision Slips

A spring that doesn’t meet spec is a liability. Load inconsistencies can cause valves to leak or stick. Out-of-square ends accelerate wear inside assemblies. Over time, those problems lead to warranty claims, system failures, or safety incidents that far outweigh the cost of doing it right the first time.

Precision doesn’t just protect the spring. It protects the brand relying on it.

The AWP Approach

Since 1995, we’ve focused solely on ground compression springs. That specialization means every investment, process improvement, and skill developed is directed toward one product with unmatched consistency. Design reviews and prototyping address challenges early and reduce risk, CNC coiling and grinding maintain tight tolerances across millions of parts, and presetting combined with rigorous testing verifies that load curves hold up under real-world conditions. The result is a lean, disciplined, and proven process that delivers defect-free springs on time with performance customers can count on.

Takeaways

Precision is the difference between a spring that supports long-term reliability and one that brings operations to a halt. AWP builds accuracy into every step, starting with certified materials and ending with validated parts that meet spec the first time and every time after.

If your next project depends on compression springs you can trust, work with a manufacturer that treats precision as standard practice. Contact Automated Wire Products today and put our expertise to work on your design.