Product type: Flat-wire compression spring
Wire profile: Rectangular flat spring steel
End treatment: Closed, precision ground flat ends
Surface finish: Dacromet zinc-aluminum flake coating (chrome-free Geomet optional)
Operating condition: Continuous cyclic compression for machinery clamping assemblies
Core performance: Consistent preload over millions of cycles, anti-corrosion for humid workshop environments

Thanks to the rectangular wire cross-section, stress distributes evenly across coil contact surfaces, delivering much higher load capacity than round-wire springs with identical outer dimensions. Ground perpendicular ends effectively avoid buckling and offset during repeated compression.

Are You an OEM Manufacturer?

Yes

Description

Project Overview of Custom Flat-wire Compression Springs

This is one of our finished custom flat-wire compression spring projects for an industrial machinery OEM.

The customer needed high-load compression springs for their clamping unit with limited installation space. Initial round wire spring trials failed to deliver sufficient force within the given dimensional envelope. Key requirements included: high load in compact size, zero hydrogen embrittlement risk for cyclic dynamic operation, minimum 500 hours salt-spray resistance, and ground ends to prevent tilting under repeated compression.

We supplied prototypes, pre-production samples and full mass-production batches using flat wire design with Dacromet coating as the final solution.

Production Workflow for Custom Flat-wire Compression Springs

Raw material: Certified spring steel, incoming material inspection performed.
CNC coiling: Precision coiling of flat profile to avoid wire section distortion.
Heat treatment: Quench & temper to stabilize elasticity and release internal stress.
End grinding: Both ends ground flat to guarantee uniform load transfer.
Shot peening: Applied to enhance fatigue life for cyclic working.
Dacromet coating: Selected instead of electroplating to eliminate hydrogen embrittlement risk; coating thickness strictly controlled without altering assembly dimensions.
Final inspection: Dimensional check, spring rate testing, coating thickness verification; saltspray test reports available upon request.

Our Custom Capabilities of Flat-wire Compression Springs

If you have similar demands: compact high-load springs, cyclic dynamic service, or non-embrittling anti-corrosion finishing, we can support your project.

Full support: prototype sampling → pre-production → mass production →Inspection & test documents available on request

Accept drawings, physical samples or performance-based specifications

Custom material, wire cross-section and end configurations

Multiple surface options: Dacromet, Geomet, zinc-nickel, black oxide etc.