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Do you have trouble finding a spring that fits in your application? Coil springs require large travel, making your application design less than optimal.
Wave washers, coil springs, disc springs, the list goes on – these are all traditional springs that work well in many engineering applications.
What if there was a more compact, light-weight design?
Whether you have space constraints, need more design flexibility, or are looking to meet a specific load requirement, adding a Smalley wave spring to your design toolkit can open up a world of new design possibilities. Knowing when to use a wave spring and understanding the value it brings can take your designs to the next level.
So when should you use a wave spring? Below are the top 6 advantages of using a wave spring.
Spring operating height can be reduced by up to 50%.
In applications with tight space constraints, Crest-to-Crest wave springs optimize space concerns. The ‘multiple waves per turn’ design can offer the same spring force as a traditional coil spring, but at a reduced operating height. A reduction in operating height also decreases the spring cavity, yielding an overall smaller assembly size. Significant cost savings may be seen with a smaller, more light-weight assembly, as it takes less time and material to produce.
Quick and economical customization with Smalley’s No-Tooling-Cost™ edgewinding manufacturing process.
We can customize wave springs to fit your exact application requirements. The number of turns, end type, material type, and thickness are just a few parameters we can customize.
Our ability to accommodate virtually any design comes from our unique edgewinding process, where we take flat wire and then coil it on edge. With the freedom to coil to nearly any diameter (0.157 – 120 in.; 4 - 3000 mm), we can efficiently optimize your design, all without the need for additional tooling.
Accurate and predictable loads are achieved by putting a tolerance on load(s) at specific working height(s).
Whether it’s a static or a dynamic application, you’re able to pinpoint the load that a wave spring outputs. This is because we tolerance critical load(s) at specified working height(s), so you can expect reliable, consistent performance in your application.
Wave spring technology is the trusted solution across many different industries and applications.
From small to large diameters, light to heavy-duty parts, carbon steel to exotic materials, wave springs has been the trusted solution for tens of thousands of applications. From everyday consumer products like the smartwatch on your wrist, or the coffee maker in your kitchen, to an oil well deep under the Earth’s surface, to as high as, well, Mars, there is virtually no limit for wave springs. Below are some examples of common applications that utilize the benefits of a wave spring.
Flow Valves: As fluid pressure increases, a Crest-to-Crest Wave Spring precisely controls the linear displacement of the piston.
Pressure Relief Valves: Air pressure under the assembly causes the spring load to increase, which forces the plate away from the sealing surface and provides a pressure relief mechanism. As pressure decreases, the spring returns to its original work height, allowing the unit to seal again.
Face Seals: The wave spring applies pressure to precisely load against a mating surface, properly sealing fluids.
Vibration Isolators: Under constant loading, the isolator dampens vibration from equipment operation. Wave springs are used to provide precise and predictable loading.
Exotic alloys are an option for your applications in extreme environments.
There are a variety of key factors when it comes to choosing the right material for your application, including environment, budget, and cycle life. Using a material that is not optimized for the environment that it’s in can lead to performance issues and decreased application life. If our carbon and 17-7 stainless steels do not meet your application’s unique requirements, we offer a variety of custom materials.
From cryogenic to high temperatures, magnetically-sensitive to electrically conductive, deep-sea to outer space, our engineering team will tailor a wave spring fit for optimal performance.
We know it’s important to ensure fit and function with prototype testing, so we offer free samples of our standards.
We also offer custom, economical prototypes that can be delivered to you in a short lead time with no minimum order quantity. This is a unique benefit of our edgewinding process, as traditional stamped parts have high up-front tooling costs, minimum order quantities, and traditionally longer lead times.
In applications with tight space constraints, Smalley wave springs are the ideal solution. Choose from over 4,000 carbon steel and stainless steel wave springs in stock, or explore a custom design with No-Tooling- Costs™. Get started with a Smalley engineer today and request a free sample to add to your design tool kit.
Interested in learning more about wave springs?
Check out our new E-Book below.
Summary Infographic
We asked Smalley marketing engineer Justyna Rapacz to fill us in on the design of wave springs and their utility to engineers designing products. We turned to Smalley as the inventor of the edge wound wave spring to provide us an authoritative explanation of the benefits of this type of spring.
Design News: What is a wave spring?
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Justyna Rapacz: A wave spring is a type of compression spring made of flat wire with a unique 'multiple waves per turn' design. This innovative design is why a wave spring can offer the same spring force as a traditional round wire coil spring but at 50 percent of its operating height.
DN: What are the primary applications for wave springs?
Justyna Rapacz: From small to large diameters, light- to heavy-duty loads, carbon steel to exotic materials, wave springs have been the trusted, space-saving solution for tens of thousands of applications. From everyday consumer products such as the smartwatch on your wrist to life-saving medical devices such as robotic surgical instruments to extreme environments like oil wells deep under the Earth's surface, to as high as Mars, there is virtually no limit for wave springs.
One common application that utilizes the benefits of a wave spring is a flow valve. While many spring systems can be designed into valves, engineers often choose wave springs because of their space-saving capability and linear compression behavior through 80 percent of the compression range. These unique features allow for more precise and repeatable control of both flow and pressure.
As fluid pressure increases, a Crest-to-Crest Wave Spring precisely controls the linear displacement of the piston.
DN: What are the benefits of using wave springs?
Justyna Rapacz: Whether you have space constraints, need more design flexibility, or are looking to meet a specific load requirement, adding a wave spring to your design tool kit can open up a world of new design possibilities. Wave springs optimize space in your assembly by providing the same spring force as an ordinary compression spring, but at a reduced operating height.
The top advantages of wave springs include:
Reduce spring height by up to 50 percent when used to replace an ordinary coil spring
Compact design fits tight radial and axial spaces, reduce spring cavity size
Light-weight assembly, save production time and material cost
Accurate and predictable load(s) toleranced at specific working height(s)
DN: What are the trade-offs if any? Cost?
Justyna Rapacz: Wave springs are the go-to compression spring when space is a constraint; however, they are not the ideal solution for applications with large travel and/or accompanied by a relatively high load requirement. Wave springs are designed for compression only, so in applications where extension or torsion is required, an alternative spring should be specified.
Cost-wise, wave springs can save you money when taking the entire assembly under consideration. Wave springs can optimize space in the assembly by providing the same spring force in a smaller space, resulting in an overall decrease in assembly size, weight, production time, and material cost. While wave springs may potentially have a higher piece price than coil springs, overall cost savings may be seen when designing a wave spring into your application.
DN: How does the choice of material affect the performance of the spring?
Justyna Rapacz: Selecting the right material is critical for optimal spring performance. There are several factors to consider during spring material selection, such as operating environment, cycle life, and budget. Standard wave springs are available in carbon steel and 17-7 stainless steel.
DN: What is your forecast for the increased use of wave springs in the future?
Justyna Rapacz: As the world around us gets smaller and smaller, space is quickly becoming a premium. Wave springs offer engineers the space-saving solution they need to meet the demand of designing modern-day, compact technology.
Are you interested in learning more about bearing wave spring washer? Contact us today to secure an expert consultation!