Category: Engineering

The term spring creates, for most people, the image of a classic helical compression spring, but this is not always the case. There are many designs for wire form springs, including torsion and tension, but flat spring pressing designs are also widely used in many applications.

What Are Flat Springs?

The first thing to note is that flat springs do not look like conventional springs. This is the most significant difference between the flat and wire form helical springs, primarily from coiled wire; the flat springs are made as flat metal strips. Classifying these pieces as springs may seem incorrect due to how different they appear. They will often look like metal pressings with no flexibility, but this rigidity is key to creating the required energy storage needed to be classed as a spring.

Metal flat spring pressings are formed into flat strips of metal that can store and release energy when compressed, stretched or bent. Once the restraining force is removed, the stored energy is released. These small components are often installed in locations requiring control deflection in restricted spaces. This usually leads to these pressings being added to more extensive mounting assemblies.

When to choose a Flat Spring or Wire Spring

Wire springs have a similar role to flat springs. They both operate with stored energy that builds when a load is presented. The advantage of choosing flat springs over coiled ones is that they can work in much tighter spaces and withstand more significant stresses without permanent damage.

Coiled wire springs are a principal component that fulfils many functions, but sometimes your application will require something more unusual, a flat spring pressing. Experienced spring suppliers such as ourselves are capable of manufacturing the highest quality wire forms and flat spring pressings to suit the specific needs of our clients.

There are many considerations when deciding on the best components for your application.

Where Would You Use Flat Springs?

Spring suppliers will manufacture flat spring pressings for a large number of applications. This will include many specific operations, such as the minor contact points within electrical circuits or installed as clips to hold mouldings for cars.

The average person can find spring clips inside picture frames as shelf edge clips or U clips in their home. Manufacturers have created flat spring pressings for cantilever springs which are flat springs supported at one end and holding a load at the other. Additionally, Belleville washers (the coned-disc spring) are flat spring pressing that supply increased flexibility to a bearing or bolted joint.

Constant-force springs

Constant-force springs are classed as flat spring pressing. This design coils around a drum (or themselves) at a constant radius. When this spring is deflected, the stress within the spring will resist the presented loading force, similar to how an extension spring operates. However, the unique factor of a constant-force spring is that they provide a consistent torque regardless of the extension length. Therefore, these springs can be found in applications with a constant load, such as cable retractors, door closers and gym equipment.

Leaf flat springs

Leaf flat springs are also used within the automotive industry for commercial vehicles. These flat springs are added to the vehicle’s suspension system to help support the entire weight, and they can also assist with regulating the wheelbase lengths when changing speed. As experienced flat leaf spring manufacturers, we manufacture flat spring pressings to suit a broad range of specifications and offer bespoke options that will suit any application.

Manufacturing Flat Springs

At European Springs, we staff skilled engineers with significant expertise in manufacturing wire forms and flat spring pressings. We understand that special consideration is required, especially when creating bespoke designs of flat springs. The versatility of flat springs needs to be considered, including deciding the material thickness, bend radius and spring geometry, all of which are dictated by the eventual application they will be used for.

Many materials are available to choose from when manufacturing your pressings:

• Aluminium
• Beryllium
• Nickel-based alloys
• Copper
• Carbon and stainless steel

These are all viable materials to choose from and are essential for creating an effective flat spring pressing, but ensuring your selecting the suitable material will depend on your application. Many carbon and stainless steels require additional treatment, such as hardening and tempering, to ensure they have sufficient strength and corrosion resistance for outdoor applications.

Our production process can be conducted either manually or automatically with our range of high-end CNC machines. You can commission one-off, hand-crafted flat springs for your custom design from us, or we can manufacture large batches of complex spring pressings to suit your needs.

Flat Spring Pressings From European Springs

At European Springs, we are a leading manufacturer of flat spring pressings in the UK. With decades of experience, our engineers can assist you every step of the way, from our custom design service to prototyping your idea and, eventually, total production. Browse our entire stock collection inside our spring catalogue, or contact us today to discuss how our flat spring service can assist your next application.

The manufacturing industry is constantly growing and changing to create the broad range of complex components our modern lives require. Metal pressings are an integral part of an almost incalculable number of applications as the metals used are highly versatile materials and can be shaped and processed in many ways.

Many manufacturers will have a stock of pressings that are known as standard (or catalogue), but more are embracing the benefits of choosing a bespoke solution.

What Are Metal Pressings?

Metal pressings (or stampings) are essential when a piece of sheet metal is formed (or pressed) with a pressing tool (or die). There are several names for the processes internationally, but they address the same method of creating the precision required for these critical metal components. The humble coin is the best-known example of a pressing, but it’s also a vital part of far more complex applications such as medical machines, electronics and defence.

Pressings are made with a flat metal sheet inserted into a specialised press and formed into the required shape with the previously mentioned pressing tool. The components created through this process may need additional treatments to meet the application’s specific needs. Punching, blanking, embossing, and flanging are all added processes to ensure the parts are precisely how they are designed.

Stock vs Custom Metal Pressings

A standard method for metal pressings can create catalogue models, but we at European springs prefer to provide more processes to generate bespoke parts. As a result, standard parts will conventionally come in predetermined sizes, materials and designs that will only apply to a set number of applications.

We understand the importance of being in control of your bespoke design when commissioning metal pressings. That is why we provide an expert metal pressing design support team to assist with any decisions about the material, surface treatment or design of your pressings. In addition, our engineers can consider the working environment, repeatability and intended product life you desire to ensure that you get pressings of the highest quality.

The choice of material is essential to get the best quality pressings and something that can be chosen as part of our bespoke service. We produce our bespoke designs from metal strips made from carbon and stainless steel and copper, brass, phosphor bronze, beryllium copper, aluminium and superalloys.

Another benefit to choosing customised pressings is that we can offer these materials in flattened wire and non-metallic materials like Melinex. In addition, we specialise in maintaining a wide range of pressings processes, such as progressive die and multi-slide stamping, so we can adapt to suit the needs of our client’s applications in small or bulk batches.

Pressings Over Fabrication

The demand for custom metal components leads manufacturers to two methods, pressings and fabrication.

When it comes to bespoke components, many believe the best solution is to choose fabrication, but this is mainly due to the misconception that it’s more effective than pressings. Metal fabrication can involve laser cutting processes that avoid the pressing stage. The disadvantage to this, however, is it’s a process more suited to prototyping or exclusively small runs as it’s a more labour-intensive approach to component creation. The increased work creates more costs making large batches significantly costly. Additionally, it’s a more complex process that makes creating particularly complex bespoke pieces increasingly challenging for manufacturers.

Even bespoke pressings are a cost-effective choice that can produce large batches of complex components with either high-quality sheet metal or durable flattened wire. In addition, these processes will provide uniform results that can be relied upon as well as reduce the waste created compared to alternative methods such as fabrication.

Benefits of Custom Metal Pressings

Component compatibility is the most noticeable benefit of choosing custom metal pressings. However, every application will be unique on some level, so whilst finding existing stock components that will fit is possible, they will not be as effective as bespoke metal pressings, custom-made for your application alone.

Reliability is guaranteed with our bespoke metal pressing service. Our engineers can monitor the manufacture of your pressings from the finalised designs through prototyping and the final batch creation. Compared to choosing standard components from alternative manufacturers, this increased attention will ensure a higher quality product.

Increased durability is always desired when commissioning metal pressings and is provided when choosing to invest in bespoke designs. However, many factors need to be considered when creating your pressings, such as the application’s environmental conditions and the stresses it will endure. For example, aerospace applications put many demands on metal pressings as they provide dramatic variations in temperature, moisture and pressures while requiring a component that can operate effectively in them all. These challenges can be overcome with expert advice from our design team engineers on materials, surface treatments and design and supply you with a cost-effective solution.

As a leading pressing and spring manufacturer in Europe we at European Springs are proud of our team’s consistent abilities to adapt to new metal pressings processes and provide high-quality pieces for our clients. Contact us today if you have any questions about our bespoke pressing service.

Metal stamping has been an integral part of the design and construction of an immense amount of products and applications. High-quality stamping has been used in many sectors, from food and beverage storage, mining equipment, healthcare and aerospace, to name a few.

As the designs for these applications become more complex, they require more intricate parts. The level of detail and diversity of these components made it necessary to develop more stamping processes and machinery that could create these pieces to a sufficiently high level of quality. Hence, the development of progressive and multi-slide stamping.

What Are Stampings?

Metal stamping (or pressing) is the creation (or forming) of a shape in metal, and this is commonly achieved with a stamping die (or a pressing tool). Pressings and stamping are so similar that the terms have become interchangeable as they both refer to the same process. Nevertheless, pressings and stampings are an essential part of our modern lives, with the number of items that need this process constantly growing. From humble objects such as coins to complex medical machines and automotive pressings, all require durable, high-quality products to work effectively. You can read more about these applications by reading our blog: imagine a world without pressings and stampings.

The general process of stamping involves adding a flat sheet of metal to a specialist machine, such as a stamping press. This flat sheet is then formed into the desired shape as a stamping die is pushed into the flat surface. This initial process can be further enhanced with additional treatments such as:

• Punching
• Blanking
• Embossing
• Bending
• Flanging

Stampings can be made from various materials to suit any application. The variety of materials is to consider the different environments that pressings will need to handle. For example, stainless steel is considered to be corrosion resistant, but aluminium is not. Strips of flattened wire can be manipulated in stainless steel, copper, brass, beryllium copper, aluminium and more to provide the best result.

As mentioned previously, the immense variety of increasingly complex designs has made it essential that stamping manufacturers have multiple processes to make the stamping and the equipment match. Two examples we provide at European Springs are progressive die stamping and multi-slide stamping.

What Is Progressive Die Stamping?

Progressive die stamping machines focus on forming a single piece of sheet metal until the final product is produced. The sheet is fed through a series of stamping areas, each designed to complete part of the overall task. This automated feeding system translates the workpiece through several regions, potentially making dozens of small additions until it reaches the end and is complete. These changes could involve cutting, bending, stamping or pressing the piece. A pilot is installed to help translate the piece and maintain precision in the changes. This pilot is fastened to pre-cut holes.

There are many advantages to this method, including reduced set-up time. Progressive die stamping uses 38% less time to set up than alternatives. This enables manufacturers to generate their lots faster and with flexibility when scheduling their projects. The machine’s design and inclusion of a pilot make repeatability with high accuracy easy.

What Is Multi-Slide Stamping?

Multi-slide stamping (also known as Four-Slide) is a process that involves using a series of tools and stamping dies to create stampings from slit coil stock or coils of wire. The stamping dyes will be mounted on opposite sides, moving horizontally in several directions. These features enable engineers to create more complex designs.

The process begins with a coil of metal fed into the machine where a series of actuated cam mechanically stamp and form the material into the required shape. This is the main advantage of using multi-slide. The complex working process can maintain a consistent accuracy as the multiple slides work at right angles to perform multiple folds (including those larger than 90°) and add cuts, punches and bend in a single step of the process. Once that’s achieved, the finished component is ejected, and the subsequent production stage commences.

One of the advantages of using Multi-Slide stamping machines is they produce significantly less waste. As a pressings manufacturer dedicated to improving our sustainability, we embrace multi-slide stamping machines as they can limit the wasted metal to 31% of what progressive die stampings commonly produce.

Our Multi-Slide department is operated by expert engineers using the best Finzer and Latour machines, which provide unparalleled flexibility of production, perfect for when intricate forming is required. Furthermore, as a manufacturer committed to being eco-friendly, we ensure that as many of the stampings we make are made from component-width material, thereby limiting any waste to minimal levels.

We design and manufacture all our tools in-house to offer our customers a low-cost solution when commissioning the creation of intricately pressed parts. If your next application requires complex pressing or stamping, you should contact our experts today and see how European Springs can help you acquire it.

At European Springs, we manufacture a wide range of springs for many different industries and bespoke pressings and wire forms, so you’re always getting exactly what you need for your project, no matter its specifications.

Our extensive catalogue includes die springs, which are considered a version of compression springs. In this article, we’re looking at what these springs are, how they work and their applications.

What are Die Springs?

First things first, knowing what die springs are can help you decide whether they’re suitable for the application you have in mind.

As part of the compression spring family, these products are made to withstand applied stress. However, unlike other compression springs, die springs are made from rectangular wire and designed to handle considerable pressure. As a result, they can take a higher load (around 30% more) and are resistant to high temperatures, as they continue to function well up to 475^oC.

The use of rectangular wire makes all the difference since it boosts the efficiency of the spring by allowing it to store more energy in a smaller space when compared to traditional springs.

How Do Die Springs Differ from Other Compression Springs?

Die springs might be similar to compression springs, but they are purposefully created to handle a large amount of environmental stress, which is why they’re also known as high force compression springs.

These products are incredibly reliable and can be designed with various strengths, perfect for several different applications. Die springs can come with closed or open ends, depending on the product’s end use, and are also colour-coded according to strength.

This allows you to easily choose the correct spring for your project – we can also help you make a decision, so chat to us on 0208 663 1800 if you have any questions we can answer.

Benefits of Die Springs

We’ve already touched on some of the advantages of using these types of springs, but they provide many other benefits, such as the following:

• Excellent performance in high-stress settings
• Resistance to high temperatures
• Available in several materials, including steel and chromium alloys
• Variety of designs and sizes
• Cost-efficient
• Handle higher loads when compared to other compression springs
• Resistant to wear and tear
• Have a great degree of flexibility when it comes to their applications
• Perfect for heavy-duty environments
• Increased fatigue life
• Reliable load-bearing surface
• Consistency when it comes to dimensional requirements

Where to Find Die Springs?

As we’re die spring manufacturers, we understand these springs are crucial in applications that require a high degree of force in a small space, which is why you can usually find them in industrial settings, such as heavy-duty machinery.

Die springs are also used in:

• Vehicles, including brakes and clutches
• Aircraft engines
• Farm equipment
• Drills, such as those found in the oil and gas sector

So, it’s clear that these high force compression springs are typically used in factories, warehouses, the transportation industry, the agricultural industry, and more. This range of uses shows how highly versatile they are!

Quality Die Spring Manufacturing

Everyone at European Springs knows the importance of quality manufacturing when it comes to springs, pressings and wire forms, and this is true of all types of products, such as die springs.

We have many years of experience in custom spring design, which allows us to understand our clients’ needs and requirements, no matter how difficult they are or how demanding their industry or sector is.

Not only do you always receive products designed to last, but you can also be confident that our springs will be delivered to you promptly so that you can take your products to market faster.

How European Springs Can Help

As bespoke pressings and spring manufacturers, we can produce both rectangular and circular wire springs, which are suitable for different applications. When manufacturing a product, we take into account factors like the material of choice, the diameter of the wire and the size of the spring, and also the environment the spring will be used in.

This helps us ensure that you’re getting the right product for your needs. Sometimes, this can mean opting for traditional compression springs instead, as they may be the better option depending on your situation – for example, die springs are not always able to compress as much as their circular counterparts. This means that if you require a spring that can travel a lot, then a compression spring is likely the better option in that case.

Our die springs are perfect for heavy-duty use, as they offer an additional degree of resistance to environmental stresses, so browse our spring catalogue or speak to us if you’re looking for a custom-made product to meet your heavy-duty requirements.

If you’re unsure whether these products are right for you, we can help by advising on the best springs for your project – just get in touch for more information. We also offer a variety of other springs from compression springs and tension springs to torsion springs.