Spring prototyping is where great spring designs either come to life—or fall flat. For engineers and designers, it’s the crucial stage where performance expectations meet real-world physics. Rushing through it or skipping key considerations can derail an entire project.

Here’s what you need to know before you move from CAD to production.

1. Define the Application Clearly

Before a spring is wound, cut, or heat-treated, engineers need to define the environment and function. Will the spring handle compression, tension, or torsion? Will it operate under high heat, corrosive environments, or dynamic loads? The answers drive everything from material choice to coil geometry.

2. Material Selection is Mission-Critical

Choosing the wrong material can tank a spring prototyping process before testing even begins. Common choices include music wire, stainless steel, and more exotic options like Inconel or phosphor bronze. Each has its own strength, corrosion resistance, and fatigue characteristics. The right material balances performance, cost, and manufacturability.

3. Tolerances Aren’t Just a Suggestion

Springs don’t live in isolation. They interact with other parts. Knowing the allowable tolerances—especially on critical dimensions like free length, outer diameter, and load at height—ensures the spring fits and functions as designed. Looser tolerances might reduce cost but can introduce performance variation.

4. Understand Prototyping Lead Times

Spring prototyping isn’t instant. Lead times typically range from a few days to several weeks depending on the complexity, material availability, and shop capacity. Communicate your timeline needs early and build flexibility into your schedule.

5. Test Early, Test Often

A spring prototype is only as good as the testing that validates it. Performance testing—load, cycle life, deflection, stress—is essential. Functional testing in the actual assembly environment is even better. It’s where issues like spring resonance, seating, or wear can surface.

6. Document Everything

Spring prototyping should generate valuable data. Keep detailed records of specs, materials, processes, and test results. That info streamlines production quoting, helps troubleshoot problems, and ensures repeatability.

7. Partner With an Experienced Spring Manufacturer

Good spring prototyping doesn’t happen in a vacuum. A trusted spring manufacturer can offer design feedback, flag manufacturability issues, and suggest cost-saving changes. Look for a partner who understands both engineering and production realities.

At Jackson Spring, we collaborate closely with engineers during the spring prototyping phase to help get it right the first time. Because once you move into production, mistakes get expensive.

Have a spring design that needs prototyping? Let’s work together to get it built, tested, and ready for production—without the surprises.