Ground Compression Springs

At Automated Wire Products (AWP), ground compression springs aren’t one product among many; they’re the only product we make. That level of focus drives a streamlined, highly refined manufacturing process built for repeatability, precision, and long-term performance.

Read on to explore the key steps behind our process and how each one contributes to delivering reliable, high-performance compression springs.

Prototyping with Production Precision

Every successful spring starts with a solid foundation. At AWP, prototyping is the first step toward flawless production. We produce all prototypes using the same CNC coiling, presetting, and grinding equipment that we use in full-scale manufacturing. That means the samples our customers receive are true representations of the final product.

Before prototyping begins, our engineers conduct a detailed design review using SMI Advanced Spring Design software. We collaborate closely with your team to validate every dimension, load requirement, and material choice. This hands-on process results in 100% Design Concurrence and a seamless path to production. Most prototypes are delivered in 10 days or less, and for select designs, same-day production and shipping is available.

CNC Coiling That Doesn’t Miss

AWP’s coiling process begins with raw materials sourced to the latest ASTM specifications. Every coil of wire comes with full material certification and lot traceability, so quality starts long before a spring is formed.

Our six Simplex-Rapid CNC coilers use dual-point control and built-in digital cameras to measure each spring’s free length in real time. Tolerances are tightly controlled; springs that pass inspection continue down the line, while any that fall out of spec are automatically sorted out and scrapped. This ensures that every part you receive meets dimensional requirements from the first part to the last.

Stress Relieving for Dimensional Stability

After coiling, each spring undergoes a stress-relieving process to stabilize its internal structure. This thermal treatment reduces residual stresses from coiling and improves the spring’s long-term dimensional stability.

Stress relieving is a vital step for maintaining tight tolerances, particularly in demanding applications where load consistency and fatigue resistance are critical. Springs that skip this step are more likely to experience distortion or early failure – something we don’t leave to chance.

Grinding for Flatness and Stability

Once stress relieved, springs move directly into our grinding department. AWP operates eight grinding machines, both CNC and mechanical, using crush and downfeed techniques depending on spring geometry and application.

We’ve built a large library of interchangeable grinding fixtures to keep springs straight and secure during processing. That includes tooling for very short springs, which many manufacturers find too difficult to handle. The result: clean, square ground ends that deliver the stability and seating performance your application demands.

Presetting for Load Consistency

Presetting is used to compress the spring to a specified height before it ever leaves our floor. This critical step helps stabilize the spring’s force characteristics and reduce long-term settling during use.

AWP offers both manual and robotic presetting solutions. Our custom-built 5-axis robotic system is designed for high-volume work and delivers unmatched precision. For low- to mid-volume programs, pneumatic and mechanical presses handle a wide range of diameters and lengths with the same attention to accuracy. No matter the volume, presetting plays a key role in delivering load stability over the life of your product.

Built-In Quality from Start to Finish

Our quality assurance process starts with incoming material and continues through final inspection. Visual checks are conducted using high-resolution video microscopes, and dimensional validation is handled using micrometers, calipers, and optical comparators. We also use computerized force testers to confirm spring loads meet the required specifications.

Statistical Process Control (SPC) is applied to monitor key dimensions and critical customer features. For programs requiring PPAP, we provide full documentation. Risk mitigation tools like PFMEA and control plans help us identify and resolve potential issues before they impact production. Every part we ship reflects our ISO 9001:2015-certified quality system and our belief that quality must be built into the process, not added at the end.

Takeaways

The manufacturing process at AWP is the result of decades of refinement, investment, and industry focus. From rapid prototyping to robotic presetting and precision grinding, every step is designed to produce compression springs that perform consistently and reliably in demanding applications.

We’ve produced over 500 million compression springs for industries that can’t afford failure, and we’re ready to support your next project, too. Contact Automated Wire Products today to request a quote or schedule a plant visit.