How to Make a Spring?

Springs are a vital component in many mechanical devices and machines. They are used to store mechanical energy and exert force.

Springs come in many shapes and sizes for different applications. While springs can be purchased pre-made, you can also piss your own usance springs in place with some basic tools and materials. Here is a step-by-step run on how to use different types of springs from scratch.

 

Materials Needed

The most common materials used for making springs are music wire, oil-tempered wire, and stainless steel. Music wire provides high strength and a good surface finish. Oil-tempered wire is heat treated before fabrication for general purpose springs.

Stainless steel offers corrosion resistance and is used where springs need to withstand moisture. Other less common materials include chrome silicon, brass, phosphor bronze, and beryllium copper.

These all have specific advantages like electrical conductivity or high temperature resistance. The material chosen depends on the spring’s operating environment and required properties. Proper selection ensures good performance and longevity.

• Metal wire or rod – Spring or mild steel is ideal. Music wire also works well.
• Mandrel or rod – A smooth round object like a dowel, bolt or pipe to wrap the wire around.
• Pliers – For bending and cutting the wire. Needle nose pliers work best.
• Clamps – To secure the mandrel while winding the spring.
• Drill – For rotating the mandrel quickly while winding the spring. A variable speed drill is ideal.
• Bench vise – To secure materials while working.
• Safety glasses – For eye protection from flying bits of wire.

Let’s dive into the beginner’s guide on how to make different types of springs from scratch.

 

How to Make a Compression Spring

Compression springs are coiled springs that compress together when a force is applied. They are often used in pens, toys, and other devices that need spring-loaded buttons or levers.

Step by Step Guide for Making a Compression Spring:

1. Cut a length of spring steel wire about 3 feet long using wire cutters. The thickness depends on the needed spring strength. 0.8-1.2mm is common.
2. Straighten any kinks in the wire using pliers. It should be as straight as possible.
3. Bend a 90-degree hook on one end with pliers. This will anchor the wire.
4. Clamp a smooth round mandrel vertically in a vise or drill.
5. Insert the hooked end of the wire into the chuck of the drill.
6. Position the wire so it touches the mandrel. Set the drill to low speed.
7. Pull the trigger and slowly wind the wire evenly around the mandrel. Coil it as tight as needed for the desired spring strength. Leave a 1/16″ gap between coils.
8. Add 10-20 extra non-touching coils at the end. Stop the drill.
9. Remove the spring from the mandrel.
10. On the loose end, bend a loop with pliers pointing inward.
11. Trim excess wire to complete the compression spring.

 

How to Make an Extension Spring

Extension springs stretch out when pulled on. They are used in screen doors, gates, and other applications where the spring needs to be extended.

Step by Step Guide for Making an Extension Spring:

1. Cut a 3-foot length of spring steel wire using wire cutters. Select the thickness based on the needed strength.
2. Straighten out any kinks in the wire using pliers.
3. Bend a 90-degree hook on each end of the wire using pliers.
4. Clamp a smooth round mandrel horizontally in a vise or drill.
5. Hook one end of the wire into the drill chuck.
6. Position the wire so it touches the mandrel. Set the drill to low speed.
7. Trigger the drill and slowly wind the wire evenly around the mandrel, coiling it tightly. Leave a 1/16″ gap between coils.
8. After winding the needed length, stop the drill.
9. Remove the spring from the mandrel and trim the excess wire.
10. The extension spring is now complete. Stretch coils apart to extend it.

 

How to Make a Torsion Spring

Torsion springs coil around an axis and twist when force is applied at the ends. They are used in clothespins, mousetraps, and other torsion-based mechanisms.

Step by Step Guide for Making a Torsion Spring:

1. Cut a 3-foot length of spring steel wire using wire cutters. Choose the thickness based on the needed strength.
2. Straighten out any kinks in the wire using pliers.
3. Bend a 90-degree angle on one end of the wire using pliers.
4. Clamp a smooth round mandrel vertically in a vise or drill.
5. Hook the bent end of the wire into the drill chuck.
6. Position the wire so it touches the mandrel. Set the drill to low speed.
7. Trigger the drill and slowly wind the wire evenly around the mandrel, coiling tightly. Leave a 1/16″ gap between coils.
8. After winding the needed length, stop the drill.
9. Remove the spring from the mandrel and trim off any excess wire.
10. Bend a 90 degree angle on the remaining straight end with pliers.
11. The torsion spring is now finished. Twist ends to wind and unleash torque energy.

 

Tips for Making Quality Springs

Creating a properly functioning spring requires carefully controlling various parameters during the DIY fabrication process. Even slight errors in material selection or coil winding technique can significantly impact the strength, durability, and performance of your homemade spring.

Before you begin making springs, keep these tips in mind to help ensure your efforts result in quality springs with the right characteristics for your intended application.

Paying attention to details like wire surface, winding tension, mandrel grip, and heat treatment will enable you to troubleshoot problems and fine-tune your spring making method for the best outcomes.

Here are some Tips:

• Use spring steel or music wire. Mild steel can also work if properly hardened.
• Mandrel diameter controls spring diameter. Use different sizes for different applications.
• Tightly coiled springs are stiffer and store more energy. Looser coiling is more flexible but weaker.
• Oil wire lightly with machine oil to reduce friction and breakage while coiling.
• Always wear safety glasses. Trimmed wire ends can fling off with great force.
• Use a bench vise and clamps to securely grip components while working.
• Go slow when coiling. Rushing can lead to uneven winding and snapping wire.
• Consistent wire thickness and coiling ensure an even, quality spring.
• Annealing (softening) wire beforehand allows tighter coiling without breaking.
• Tempering springs after forming increases hardness and improves elasticity.

 

Advanced Spring Making Techniques

Advanced techniques in spring making involve computer numerical control (CNC) machinery. CNC coilers precisely control diameter, pitch, and other parameters. Automated processes improve efficiency and quality.

Heat treatment like quenching and tempering modifies the metal’s crystalline structure for increased durability and temperature resistance. Shot peening compresses the surface to improve fatigue life.

Testing procedures like fatigue life assessment ensure proper performance. Surface treatments like plating improve corrosion resistance and aesthetics. Precision grinding and finishing provide smooth, consistent springs.

Prototyping and simulations optimize designs. Advanced techniques enable high-volume production of reliable, customized springs.

While basic springs can be handmade with simple tools, those looking to make more complex springs can utilize more advanced equipment and techniques.

Here are some to the advanced spring making techniques:

Spring Winding Machines

• Specialized tools that greatly speed up spring production.
• Allow precise winding of springs with consistent coiling and geometry.
• Provide features like tension control, automatic feed, and coiling guides.
• Models range from DIY 3D printed tools to industrial winding machines.

Heat Treating

• Heating and rapidly cooling steel in oil or water harden it through quenching.
• Tempering afterward, by heating to a lower temperature, removes brittleness while maintaining spring properties.
• Allows the use of softer wires that can be coiled tighter without breaking.
• Done with torches, ovens, or industrial furnaces.

CNC Mandrel Winding

• Computer controlled spring winding around a mandrel by machine.
• Achieves highly precise, automated, and efficient spring fabrication.
• Makes complex spring shapes possible beyond simple linear coiling.
• Needs CNC winding equipment, specialized software, and programming.

3D Printed Springs

• Direct 3D printing of springs with flexible filaments like NinjaFlex.
• Allows complete customization of spring design and geometry.
• Limited by weaker strength of printed materials vs spring steel.
• Mainly useful for prototypes before fabricating the final metal springs.

 

Spring Design Considerations

Several key factors must be considered when designing a spring. The operating environment determines suitable materials based on temperature, corrosion resistance, and other conditions.

Dimensions like wire diameter, mean coil diameter, and number of active coils significantly impact the spring’s stiffness and load capacity. End types affect load transfer and stability.

Preload and solid height relative to free length prevent buckling while allowing full deflection. The outer diameter and inner diameter must provide proper clearances for smooth operation. Stress levels and safety factors ensure the spring withstands expected loads without failure.

Testing validates the design through fatigue testing, stress analysis, and other methods. Thoughtful design optimizes spring performance for the intended application.

Some spring design considerations are:

• Spring diameter – Thicker wire and smaller coils yield greater stiffness and load capacity.
• Coil spacing – Compact coils increase stiffness but may exceed material elastic limits.
• Total coils – More coils increase the working length but also the stiffness.
• Material thickness – Thicker wire is stiffer but harder to coil tightly.
• End loops and hooks – Important for interfacing the spring with other components.
• Environment – Springs may require coatings or treatments to resist corrosion.
• Cyclic fatigue life – Maximum stress should be under material endurance limit.
• Temperature – Extremes can impact material properties and performance.
• Static load capacity – Determine the maximum load before yielding or taking a permanent set.

 

Common Spring Applications

Springs have many common applications in everyday products. Compression springs provide resistance in push buttons and valves. Extension springs separate objects like retractable pens.

Torsion springs store energy indoors, clamps, and hinges. Leaf springs absorb shocks like in vehicle suspensions. Helical springs support weight and allow motion in mattresses, sofas, and car seats.

Small springs provide force in switches, locks, and medical devices. Springs counterbalance weight in trunk lids and reclining furniture. They store energy in toys and clocks. Springs maintain contact with electronics.

Their flexibility and customizability make them vital in many machines and consumer goods.

• Vehicle suspension – Absorbs shocks from road bumps and vibration.
• Valves – Provide closing force and sealing.
• Screen doors – Counteract swinging and self-close.
• Mattresses – Support body weight and allow cushioning.
• Pens – Retract and extend the ballpoint tip.
• Toys – Power hopping or jumping mechanisms.
• Switches – Snap buttons or keys into position and return.
• Locks and latches – Provide opening and closing force.
• Watches and clocks – Regulate timing and drive motion.
• Appliances – Counteract door slamming or flapping.

 

 

Frequently Asked Questions About Making Springs

 

1. What types of metal are best for making springs?

   The best metals for handmaking springs are spring steel and music wire. Spring steel has a high carbon content, making it very elastic and able to resist taking a permanent set. Music wire is stiff and durable. Mild steel can work if properly hardened through heat treatment.

2. What thickness of wire should be used?

   Thicker wire coils are stiffer and can handle more load. But they are harder to coil tightly. Wire of 0.8-1.2mm diameter is commonly used for small springs. For lighter duty springs, thinner wire down to 0.2mm can work.

3. What tools are needed?

   At a minimum, pliers, mandrels, clamps, drills, and cutters are needed. A bench vise and safety glasses are also highly recommended. For advanced techniques, winding machines and heat treating equipment are used.

4. How tight should the coils be?

   Tighter coiling stores more energy and makes a stiffer spring, but increases stress on the wire. Leave at least 1/16″ between coils as a minimum. Reduce spacing for a stronger spring.

5. How are springs heat treated?

   Heating steel hot enough to glow red, then quenching rapidly in oil or water, hardens the steel through rapid cooling. Tempering afterward reduces brittleness while maintaining spring properties.

6. How long should springs be?

   The length depends on the total deflection and stretch needed. But longer springs can buckle and tangle. Keeping lengths under 1 foot for small springs prevents issues. For longer extensions, multiple springs can be combined in series.

7. How are custom geometries made?

   For non-linear shapes, CNC mandrel winding machines allow complex programming of spring shapes. 3D printing using flexible filament can also create custom spring geometry.

8. How are springs safely handled?

   Always wear safety glasses when making springs. Trimmed ends and broken wires can injure the eyes. Use pliers and clamps instead of fingers when possible to avoid pinching and cuts.

9. How are springs lubricated?

   Light oil lubrication reduces friction, heat, and wear when coiling. It allows tighter winding without breaking the wire. Remove excess oil after forming to prevent the collection of dirt and debris.

10. How long do springs last?

    Spring life depends on material, design, and loading. Exceeding maximum stress and fatigue limits causes early failure. Proper design and limiting loads result in virtually indefinite life.

 

Key Facts about How to Make a Spring

Some key facts about spring making:

• Music wire and stainless steel are the most common materials. Chrome silicon is also popular.
• CNC machinery enables precision and automation. Heat treating improves properties.
• Testing ensures proper performance. Surface treatments add protection.
• Compression springs resist linear forces. Extension springs separate under tension.
• Torsion springs store rotational energy. Leaf springs absorb shocks.
• Springs provide force, motion, shock absorption, and energy storage.
• Customization allows optimal performance for any application.

Materials

• The most common materials used are steel alloys like high carbon steel and stainless steel due to their strength, durability, and cost. Other options include copper alloys and nickel alloys.

Manufacturing Process

• Compression springs are made by coiling or winding spring wire around a cylinder using specialized spring coiling machinery.

Spring Design

• Key parameters that need to be considered in compression spring design:
  • Wire diameter – affects spring stiffness
  • Coil diameter
  • Number of coils – more coils increases spring stiffness
  • Pitch – space between coils
  • End types – closed and ground, closed and unground, open and unground
• Compression springs can have different coil shapes like cylindrical, conical, barrel, and hourglass.

Applications

• Compression springs are used in a wide variety of applications including:
  • Vehicle suspensions
  • Mattresses
  • Appliances
  • Doors
  • Switches
  • Valves
  • Medical devices

They provide resistance between components, absorb shocks, and store potential energy. Compression springs are manufactured by coiling spring steel wire on specialized machinery.

Key design factors include wire diameter, coil diameter, and shape, number of coils, pitch, and end types. They are used in many applications where their ability to store energy and provide resistance is needed.

Learning how to make your springs empowers you to create custom solutions for projects that need elasticity, shock absorption, force generation, or motion control. With some simple tools and materials, springs can be hand fabricated using basic mechanical techniques.

The process also builds valuable metalworking skills and a deeper understanding of this fundamental component found in many mechanical systems.

Whether you need a unique spring solution for a hobby project or prototype, knowing how to wind and form your own springs is a good skill to add to your repertoire.