How are springs made? The Boynes definitive spring manufacturing guide.

Tension Springs Perth, Australia - Boynes Springs

We’ve been manufacturing custom springs for 55+ years and it’s safe to say we know a thing or two about the humble spring! At Boynes, we can make a spring out of just about any spring material – always to high standards and tested rigorously while providing you with relevant industry knowledge to ensure your spring does the job right. 

So, if you’re asking yourself the question “how are springs made?”, you’ve definitely come to the right place. 

The coil spring manufacturing process

  1. Know your need. Before we begin manufacturing your spring, we’ll discuss your spring requirements, that is, things like load-bearing requirements, resilience, size, temperature/element conditions of use and what you are trying to achieve. With Boynes Springs your spring solution is completely fit-to-purpose. If you’re not sure of your exact requirements, call in the experts – that’s what we’re here for!
  2. Select and prepare materials. We’ll identify the right type of material to align your needs with the alloy that will give you the best outcome. You can use our alloy specifier tool online to help with this too!
  3. Coiling using a mandrel coiler. This process rolls your alloy wire into the correct shape for your custom requirements, whether it’s a clock spring, cone compression spring, die spring, tension spring or torsion spring! It is then removed from the shaft and then stress relieved or heat treated depending on its requirements. 
  4. Heat processing. Whether cold-formed or hot-formed, the coiling process causes some stress in the wire, so a heat treating  process sets the spring for long-lasting reliability. Depending on the size, material and requirements of your spring, we’ll customise the heat setting time and temperature to ensure the ideal results.
  5. Removing surface imperfections. This process is called shot peening and uses a machine to shot small metal pieces at the spring surface which helps to remove any microscopic cracks in the material. This in turn, helps to improve the life time of the spring.
  6. Setting your spring. This process is used to ensure the correct recoil for your spring so that it will function properly. It will be adjusted multiple times to ensure it will remain stable at a set length.
  7. Final stage – coating. Depending on your requirement, if needed, this step is done to prevent corrosion and ensure your spring is fit for its end purpose. Coatings can include liquid rubber, powder coating or plating with another metal. 

And there you have it – coil spring manufacturing in a nutshell! If you have special requirements such as high-strength needs or if you need a spring that pushes together rather than pulls apart, read on for more details. 

Industrial spring manufacturing
For heavy-duty use, we recommend opting for specific high-tensile materials. We have the option of Range 3 metals for your springs, which provide a better spring memory than the industry-standard Range 2 metals. Range 3 metals have a longer lifespan, can withstand more cycles and have better resilience making them ideal for frequent or high impact use. 

Across the board, we use only high-grade, hyper-durable Korean and European standard steel. We have a rigorous in-house quality assurance process and we’re ISO 9001:2000 compliant, so you can rest assured any Boynes’ product will go the distance.

Compressed spring manufacturing
Compression springs are also a coil spring form, however, they are an open-coil helical spring, so the wire looks pre-stretched – just like the spring in a ballpoint pen. Sometimes used with a rod inside or fitted within a hole to eliminate buckling, compression springs absorb energy and condense and push back into shape depending on the application. From basic installation inside buttons to automotive engines, stamping machines and major appliances or machines, compression springs are a reliable and energy-efficient tool for movement with hundreds of thousands of uses. 

We hold a range of standard sized compression springs and we also manufacture custom compression springs for specialist requirements. 

We’re your industry-leading spring manufacturing specialist!
Can you believe Boynes Springs has been manufacturing springs in Perth since 1966? We now have 2nd and 3rd generation family metal workers working within our business, with a shared passion for getting your reliable custom spring solutions to you within a 2-week turnaround – that’s a guarantee! 

Get in touch with our team to discuss your requirements or check out our blog ‘4 things you need to know when custom designing a spring’ for more information about custom spring manufacturing. 

Contact us today!