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We deliver advanced spring manufacturing processes and production systems through state-of-the-art machinery, engineering expertise and software across the very latest and widest range of large-scale, high-end hot and cold spring coiling machines, providing the highest quality precision springs.
Essentially straight wire is fed into a coiler through a number of coiling rollers that lead to a set of coiling points that apply pressure to create the precision spring product. Seemingly simple when looking at our video but years of engineering expertise and advanced technologies ensure the process of bespoke manufacturing a metal spring is precise, efficient, fit for purpose and secures a quality, accurate product with the longevity of use.
The coil spring manufacturing process starts with a client consultation, then design, and progresses to material selection before passing through a number of development, manufacturing and production processes. As specialist heavy spring manufacturing experts our spring manufacturing process includes hot and cold coiling spring manufacturing equipment, including the largest Wafios CNC coiler in the world. The coiling is just part of the journey, as the full spring manufacturing process also requires heat treatment, shot peening, grinding, powder coating and finishing
Our suite of CNC spring coiling machines manufacture compression springs, tension springs and torsion springs in a wide range of materials in wire diameters from 0.5mm to 65mm. We cold coil wire up to 30mm wire diameter and hot coil up to 65mm. However, we are always expanding our capabilities and are happy to discuss larger wire size projects.
Our digital technology extends to 3D scanners, precisely measuring tolerances and offering a digital archive for each customer. All our CNC coilers have secure VPN links to enable regular testing and diagnosing of accuracy levels and our computerised maintenance management systems ensures peak efficiency across the spring manufacturing process.
With a wealth of grinding technology including horizontal, vertical, wet and dry grinders, alongside multiple shot peeners, powder coating lines, fully computerised and calibrated stress testers and automated pre-stress machines, as well as inhouse material scientists and testing facilities, we offer a complete concept to completion coil spring manufacturing process.
An advanced range of highly technical, quality assured and industry recognised spring machine brands feature across our CNC coiling machines delivering quality, accuracy, the best production run rates and efficiencies across an extensive wire range. If you need springs manufactured in accordance with the finest tolerances, our CNC spring coiling machines ensure a level of reliability that negates the risk of defects.
Multiple in-line conveyor belt ovens deliver a stress relieving process which enables the spring to retain its shape and functionality when put under stress – whether it be compression, torsion or tension.
Our heat treatment capabilities are fully automated and computer controlled for maximising the demands of the material and spring formation.
Compression springs commonly require the end of the coil to be shaped flat or square to suit the need of the application of that spring. With millions of compression coil springs manufactured for multiple applications and industries we feature an extensive range of horizontal, vertical, wet and dry grinders to deliver absolute accuracy at the applications implementation stage.
Our 3D optical measuring and testing scanners utilise high quality cameras and laser technologies, enabling contactless, fast and digital quality controls. It also allows us to keep a digital library for production processing and customer sampling.
Expanding, accelerating and simplifying our production lines through automation and robotics reduces margins of error and enhances cost efficiencies for you.
Our facilities include a number of robotic functionalities and automated systems, all designed to optimise production efficiencies.
Large scale, fully automated and computer-controlled powder coat lines offer a zinc phosphate coating option in advance of powder coating, delivering 1000 hours of corrosive salt spray resistance. Have a brand colour? Want us to match your RAL or Pantone? We can facilitate a wealth of different colours and are expanding our powder coating paint palette all the time.
We can also print individual part numbers on all your products.
With multiple in-line shot peening facilities, we can improve your components shelf life and fatigue performance by making it more resistant to cracking and corrosion. Shot peening adds a compressive force to the outside of the spring, which inhibits crack propagation and therefore increases fatigue life.
Testing the stress on a spring is a key part of the spring manufacturing process to ensure the spring design, material and method of manufacture is fit for purpose. Our fully computerised, calibrated and regularly reviewed spring load testing units can precisely assess the fatigue life and creep of your spring.
We also feature a bespoke designed, fully automated pre-stress machine for large volume batch testing.
CNC coilers allow for increased accuracy, rapid set up times and agility, which leads to quick turnaround times and most importantly our industry recognised high quality springs. Our coil spring manufacturing is renowned for its quality springs, secured through the industry’s most advanced CNC spring coiling machines.
Our fleet of hot coiling spring machines and cold coil spring equipment allow us to manufacture heavy duty springs across a large wire diameter, supplying industries all over the world.
We manufacture millions of compression springs every year and the compression spring manufacturing process is mesmerising to witness.
Multi-staged, the wire material is fed through a wire straightener before being coiled into the desired compression spring size.
Compression springs are the most common type of springs, with a unique design meaning that their compressed, helix shape allows them to resist compressive forces, delivering strength and elasticity designed to keep components apart.
They can be manufactured into cylindrical, conical, tapered, convex or concave shapes with a constant or variable pitch, and with either ground or unground ends.
Our engineering experts deliver a wealth of material knowledge and our inhouse material scientists are the best in their field, on hand to advise on the right material for the right environment for the right application.
With an extensive range of spring material choices across stainless steel springs, nickel alloy and chrome silicon steel as well as numerous other materials including a diverse range of steels, copper and titanium alloys, as well as super alloys, including Inconel, Hastelloy and Nimonic, we have a material to suit every spring requirement and purpose.
Powder coating coil springs is required by a high volume of our customers. Many request a specific colour, often in alignment with their recognised brand and to enhance the appearance of the performance spring – you’ll spot a number of our springs across a number of motorsport disciplines as well as on domestic bikes and cars.
We’re often asked if we can powder coat springs and we can across a wide variety of colours. If plating is required, we have reliable suppliers that we subcontract to deliver this.
Powder coating can be applied in a variety of thicknesses and finishes and our team are on hand to discuss any specific requirements.
Bespoke spring manufacture is our specialism. Designing springs from conception, that deliver a specific function for specific applications across every industry.
Experts in theoretical modelling and prototyping, at assessing stress levels and evaluating creep or fatigue performances, our design engineers consult with you to tailor the length, force, movement, damping, connectors, colour and finish of your spring requirements.
Our expertise lies in custom spring manufacture, ensuring you achieve the optimum performance from the spring component part of your product.
Striving to deliver environmentally sustainable solutions, securing ethical metals and continuously developing and committing to ISO 14001 and ISO 9001 standards keeps our teams laser-focused on our environment and quality management systems.
We explore sustainability across our environmental, economic and social practices.
Explore our group policies, including our quality and environment policy, sustainability policy, conflict minerals and ethically sourced metals policy, code of conduct and sustainability reports.
Springs are manufactured through either hot or cold coiling manufacturing processes from an array of materials across varying wire diameters; the design, material and manufacturing processes are specifically designed for a springs engineered purpose.
CNC coilers provide the most accurate, efficient and high quality of springs.
Springs can be made from a wide range of materials. Material choice is led by the application of the spring within the environment it is working.
Tension springs are manufactured by CNC coilers. Our engineers consult on a number of points to ascertain the best method of spring manufacturing process for your spring. These include:
- What are the spring dimensions required?
- What end fitting is required?
- What force is required?
- Can we find the maximum tension of the spring?
- What is the expected working environment of the expansion spring?
- What is its expected spring fatigue life?
We are world-leading heavy duty spring manufacturers, delivering the greatest expertise in compression, torsion and tension spring manufacturing.
Delivering impact to every industry, we guarantee spring solutions that will optimise your performance and success.
