Flat springs and shaped springs made from flat material are playing an increasingly important role in construction technology. These components made from spring steel strip or spring sheet offer designers unique opportunities to elegantly solve complex technical challenges. While classic flat springs have been tried and tested for decades, modern form springs open up completely new dimensions of geometric design freedom and functional integration.
Table of Contents
Basics and functional principle
Flat springs and shaped springs are manufactured from spring steel strip or spring sheet. Various manufacturing processes such as laser cutting, punching, wire erosion, CNC punching and bending centers and a wide variety of forming processes are used. The basic principle of the flat spring and shaped spring is based on the elastic deformation of the spring steel, whereby energy is absorbed under load and released again when the load is removed.
The key difference between classic flat springs and modern form springs lies in their geometric complexity. While traditional flat springs usually have simple, rectangular geometries, shaped springs can realize almost any contours and three-dimensional structures. This design freedom makes it possible to combine several functions in a single component while making optimum use of the available installation space.
Constructive possibilities and design freedom
The design of flat springs and shaped springs offers exceptional variety. Not only can the desired spring properties be determined through targeted shaping, but additional functions can also be integrated. For example, a flat spring or shaped spring can be designed in such a way that it simultaneously functions as a force, guide, fastening element and electrical contact. Integrated fastening lugs, stops, contact surfaces or guide elements make the flat spring and shaped spring an all-rounder and significantly simplify design and assembly. This design freedom makes the form spring and flat spring ideal components for multifunctional and optimized designs.
Calculation approaches and design
The design of an optimum flat spring or shaped spring requires many years of sound practical experience. Especially with the individual and complex shape of the form spring, a standardized design by calculating bending radii and bending stresses is only possible to a limited extent. The design of a form spring is therefore carried out iteratively with a strength and functional verification, often with the support of CAE software with finite element analyses. For this reason, Gutekunst Formfedern documents design-relevant information for subsequent designs and calculations in detail for each production run.
The stress concentration at corners and transitions deserves special attention during design. These critical areas often determine the service life of the entire metal spring. A sophisticated design with optimum bending radii and transitions as well as well thought-out force transmission to the flat spring and shaped spring can prevent dangerous stress concentrations.
The right choice of material for the respective application plays a decisive role. Whether for high or low temperatures, corrosive or aggressive ambient media, food-safe, medically pure or electrically conductive applications. There are high-quality spring steel grades and subsequent surface treatments that offer high reliability for the respective application.
Manufacturing technologies and quality assurance
Modern production technologies enable the precise manufacture of flat springs and shaped springs. Depending on the requirements, shape and quantity, the finished stamping and bending process is used for large series as well as the separate cutting and bending process for small and medium series. In addition to classic laser cutting, water jet cutting is also used for thicker materials and wire erosion for thin and delicate parts. CNC-controlled bending centers and automatic bending machines as well as individual bending and forming tools are used for subsequent forming. There are no limits to the design of shaped springs.
Final surface treatments such as vibratory grinding, barrel finishing, phosphating, burnishing, galvanizing, painting and many more are offered as well as the pressing in of threaded bolts, for example, or direct installation in assemblies provided. In addition to standard spring strip steels and spring steel sheets, numerous stainless steels, non-ferrous metals and non-ferrous metals are offered in strip or plate form for the production of flat springs and shaped springs.
Variety of applications in practice
Flat springs and shaped springs made from flat material can be found in almost all areas of industry. In the automotive industry, they are used as contact springs in electronic systems, as clamping springs for fastenings, as sensor elements in measuring systems or as complex actuating springs in switching mechanisms. Their compact design makes them ideal for modern, compact applications in vehicle construction.
Electrical engineering uses the precise electrical properties for contact applications. Defined contact forces and optimized current conduction are essential here. Moulded springs can perform mechanical and electrical functions at the same time. Special surface coatings ensure long-term stable electrical properties even under difficult environmental conditions.
In mechanical engineering, flat springs and shaped springs enable innovative solutions for handling technology and automation. Their precision makes them ideal components for measuring and dosing applications where reproducible spring characteristics are required. Complex gripper mechanisms or positioning systems benefit from the functional integration of modern form springs.
Medical technology places special demands on biocompatibility and precision. Molded springs made of stainless steel enable the most delicate mechanisms in medical devices. The ability to realize complex functions in the smallest installation spaces is invaluable here.
Development trends and future prospects
The development of flat springs and shaped springs is moving towards miniaturization and functional integration. Modern CAD systems and simulation software make it possible to find optimum solutions as early as the development phase. New spring materials and surface treatments open up additional possibilities. High-strength spring steel grades allow even more compact designs, while new special alloys and surface coatings enable ever better extreme environmental conditions and functional diversity.
The optimal solutions
The success of flat spring and shaped spring designs depends crucially on early cooperation between the designer and the spring specialist. Production engineering aspects and material properties should be taken into account as early as the concept phase. The expertise of experienced form spring manufacturers is indispensable for the realization of an optimal solution. A systematic requirements analysis forms the foundation of every successful development. Web force curves, service life requirements, environmental conditions and installation situation must be precisely defined. The exact specification of all functions and their interactions is particularly crucial for form springs.
Flat springs and shaped springs made of flat material are more than just elastic components – they are often key components for innovative product solutions. Their unique combination of design freedom, precision and functional integration makes them indispensable elements of modern designs. The continuous further development of materials, production technologies and calculation methods is constantly opening up new application possibilities.
Do you need application-specific flat springs, shaped springs, contact springs, spring clips or metal clips? Then just send us using the following Request button the data of the desired technical spring including drawing or CAD data as well as the request quantity. Gutekunst form springs develops and manufactures individual metal springs as samples, prototypes, in small quantities and large series. We will prepare a non-binding offer for you at short notice. You can also contact our experts directly. You can contact the Gutekunst Formfedern technical department by telephone on (+49) 07445 85160 or by e-mail at konstruktion@gutekunst-formfedern.de
Benefit from the new Formfedern store
The new form spring store from Gutekunst Formfedern offers several advantages in the procurement of form springs, flat springs, laser parts and sheet metal parts. Thanks to its simple operation, transparent online price calculation and fast digital processing, it is a real support for designers, technicians and purchasers. At last, it is possible to configure, calculate prices, make inquiries and place orders for tailor-made formed metal parts in an uncomplicated and time-saving manner – around the clock and with maximum transparency.
Try it out for yourself at https://shop.formfedern.com
Form Springs Shop
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