Choose the Right Spring Type

Start by identifying the primary load type. Compression springs resist push forces and are the most common choice for applications like valve returns or shock absorption. Extension springs handle pull forces, such as in garage doors or trampolines. Torsion springs deliver torque around an axis, ideal for clip mechanisms or hinges.

Consider space constraints. Compression springs need room to buckle, so use a guide or rod for long, slender designs. Extension springs require end hooks or loops—beware of stress concentration at the bends. Torsion springs need mounting points for the legs and clearance for angular deflection.

Match material to environment. Music wire (high carbon steel) is cost-effective for dry, indoor uses. Stainless steel (302/304) resists corrosion for outdoor or medical equipment. For high temperatures, use Inconel or 17-7 PH. Never forget: higher tensile strength often means less deflection for the same wire diameter.

A simple rule: if you need linear force, pick a compression spring; if linear pull, choose extension; if rotational force, go with torsion. Always verify the operating range stays below 80% of the spring’s maximum deflection to prevent fatigue failure. Prototype and test under real loads—spring data sheets are a starting point, not gospel.

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