Manufacturing Ground Compression Springs

At AWP, we manufacture ground compression springs with a commitment to reliability, efficiency, and high-quality performance. Since 1995, we’ve developed a streamlined, results-driven approach that delivers springs tailored to the toughest application demands.

From design and prototyping to CNC coiling, grinding, presetting, and quality assurance, we follow a well-structured process that maximizes consistency, durability, and repeatability. Let’s walk through how we manufacture ground compression springs from start to finish.

Prototyping & Design Review: Setting the Foundation

Every successful compression spring starts with a well-developed design. AWP collaborates with customers to refine specifications, improve manufacturability, and eliminate potential production issues.

Our Approach:

✔ Comprehensive Design Review: Our team examines wire diameter, coil pitch, free length, and load requirements to fine-tune the design.
✔ Collaborative Adjustments: Working closely with customers, we make modifications that streamline production and enhance performance.
✔ Production-Ready Prototypes: Prototypes are made using the same CNC coiling and grinding equipment as full-scale production, allowing for a smooth transition to manufacturing.
✔ Fast Turnaround: Lead times as short as 10 days – or even same-day production for select projects – help keep your project on track.

Material Sourcing: Building Springs with High-Quality Materials

The durability of a compression spring depends on the materials used. AWP sources carbon steel, stainless steel, and specialty alloys to match the specific needs of each application.

Why Material Selection Matters:

• Diverse Options: Whether it’s corrosion-resistant stainless steel or a high-strength alloy, we select materials suited for demanding environments.
• Certified & Traceable: Every batch meets industry standards and comes with full documentation for traceability.
• Optimized for Performance: Material choices factor in strength, flexibility, and environmental conditions to extend product lifespan.

CNC Spring Coiling: Accuracy in Every Coil

AWP has invested $2.5 million in Simplex-Rapid CNC coiling technology to manufacture high-quality ground compression springs. Our six advanced CNC coilers deliver consistent, repeatable results for projects of all sizes.

Key Features of Our CNC Coiling Process:

• Digital Measurement Cameras: Every spring is measured for free-length accuracy before being cut, preventing variations.
• In-Line Sorting Chutes: Springs that don’t meet exact specifications are automatically removed, ensuring only flawless parts proceed.
• Production Flexibility: We manufacture springs with wire diameters from 0.008″ to 0.200″, supporting industries like fluid power, agriculture, and construction.

Our advanced CNC coiling technology provides unmatched uniformity and reduces defects, keeping production efficient and cost-effective.

Spring End Grinding: Achieving Flat, Parallel Ends

Flat ends help compression springs function properly by providing stability and uniform load distribution. We’ve built grinding into our core operations, producing springs that meet exacting requirements.

Our Grinding Capabilities:

• Crush Grinding: Ideal for small to medium springs, this process grinds multiple springs in a single pass for efficiency.
• Downfeed Grinding: Uses incremental passes to fine-tune spring height and squareness for large or complex designs.
• Custom Grinding Fixtures: Specialized tooling holds springs straight during grinding, eliminating inconsistencies.

With over 500 million ground compression springs produced, AWP is highly experienced in delivering uniform, high-performance springs.

Presetting: Strengthening Spring Performance

To improve long-term reliability, AWP incorporates presetting, a process that compresses springs to a fixed height before final production. This stabilizes the load characteristics and helps springs maintain their designed properties over time.

Why Presetting Matters:

• Maintains Load Stability: Reduces settling and preserves intended performance across repeated use.
• Extends Spring Life: Helps prevent premature weakening or deformation under stress.
• Automated Consistency: Our 5-axis robotic presetting system applies uniform force across large-scale production runs.

With this extra step, we deliver durable, application-ready springs that stand up to repeated compression cycles.

Quality Assurance: Excellence in Every Spring

Quality is not just a step in our process – it’s built into every stage of production. AWP follows ISO 9001:2015-certified quality control procedures, using advanced inspection technology to verify each spring’s specifications.

How We Maintain High Standards:

• Visual Inspection: Every spring undergoes a detailed video microscope analysis to check for defects.
• Dimensional Testing: Micrometers, calipers, and optical comparators verify wire diameter, coil spacing, and free length.
• Load Testing: Computerized force testers confirm that each spring meets its intended performance criteria.

We also integrate Statistical Process Control (SPC) to monitor consistency throughout production, minimizing variability and waste.

AWP: Your Trusted Partner for Ground Compression Springs

From design to delivery, AWP has built a process that emphasizes efficiency, repeatability, and reliability. Whether you need rapid prototyping, CNC coiling, precise grinding, or rigorous quality control, we are ready to deliver.

• Industry Experience: More than 30 years of manufacturing excellence
• Advanced Technology: CNC coilers, robotic automation, and in-line quality control
• Fast Lead Times: Prototyping in 10 days or less
• Defect-Free Production: Stringent quality checks at every stage

If you need high-performance ground compression springs with guaranteed consistency, AWP is ready to help.

Contact us today to discuss your project and experience the AWP advantage firsthand.