Are you designing your spring for
performance, manufacturability, or both?
There are several factors that go into the cost of manufacturing a spring. Many times, raw material makes up only a portion of the total price. Once you receive the springs, there could be additional costs involved if you need to untangle or orientate them for an automatic feeder.
Beyond the desired performance of the spring, there are several other factors that should be considered in the design phase. That is why it is important to consider the spring requirements early in the product design process and to work with an experienced spring designer that can help get the best functionality at the lowest price!
Spring coiling machines have limitations. Several different coilers may be able to run a part, but certain coilers can run it faster. The faster run times result in cost savings. Sometimes that savings could be 30% or more! Are you designing your springs with that in mind? Typically, springs are one of the last components designed into a part. The requirements are determined, and the software determines the required spring. With just the slightest change, a spring could have the same functionality, but be able to be coiled must faster.
What is the cost to untangle coils on the production floor? What does it cost for the spring supplier to place each spring on tack board? In certain applications, springs can be redesigned to avoid tangling, while still providing the required functionality.
Many times, when designing a spring, an engineer will choose high carbon wire because of its availability and low cost. When rust prevention is required, the springs will be plated. In certain applications, the cost of stainless-steel wire may be less than plating the high carbon wire. How would an engineer know this without consulting a spring supplier? Also, what are the ramifications of the extra handling and possible plating inconsistencies?