A spring, at its simplest, has not changed. It stores energy through elastic deformation and releases it in a controlled way. Whether it sits within a hinge, valve, safety mechanism or actuator, the underlying principle remains the same as it was decades ago. But how has springmaking evolved over the years?
The context in which that simple function operates has, however, shifted considerably. Over the past 55 years, expectations around repeatability, traceability and proof of performance have increased as the systems springs support have become more sophisticated and the consequences of failure more severe.
At Micro Spring & Presswork, founded in 1964 and now in its 62nd year, we have seen that shift at close range. Springs were once often treated as relatively straightforward components. Today, they are recognised as critical features within assemblies, influencing reliability, safety and overall product performance. A spring can determine whether a mechanism operates smoothly over millions of cycles, whether a system meets validation requirements, or whether a product reaches its intended service life.
The industries we serve reflect that growing importance. Aerospace, defence and oil & gas applications demand high levels of consistency and reliability. Subsea and marine environments introduce corrosion, pressure and accessibility challenges, while space and clean energy applications push the limits of performance, durability and weight. Although the mechanical principle remains simple, the expectations surrounding design and manufacture have become more involved.
Why is hands-on expertise still important?
In earlier decades, much of spring production relied on cam-driven machinery and experienced operators. These machines were capable of producing excellent parts, but consistency often depended on the individual. Set-ups required careful adjustment, troubleshooting relied on practical judgement, and many of the subtleties that affected performance were retained as knowledge on the shop floor rather than within formal systems.
That hands-on expertise still matters. Springs are sensitive to variation, and small changes in material condition, tooling wear or forming stresses can influence load characteristics, free length, spring rate and fatigue life. What has changed is how those variables are managed. Modern springmaking aims to capture and control them systematically. Where operators would once compensate through experience, today’s processes are designed to build consistency into production from the outset.
This is not a shift away from craftsmanship, but an extension of it. Engineering insight is applied earlier in the process, transforming individual skill into repeatable capability. Functional requirements are translated into stable manufacturing methods that can be reproduced reliably over time. Expertise still sits at the heart of the process, but it is now embedded within programming, process development and quality frameworks as much as it is within manual adjustment.
The introduction of CNC technology marked a key step in that transition. CNC machinery did more than improve efficiency. It changed expectations around control and repeatability. Manufacturing parameters could be programmed, stored and recalled, enabling consistent production across batches and over longer timeframes.
This level of control also opened up new possibilities in design. More complex geometries, tighter tolerances and demanding performance requirements became achievable because the process could be managed with greater precision. Springs increasingly moved away from standard catalogue parts towards application-specific solutions.
Alongside advances in manufacturing, digital design tools have reshaped development. Calculations that were once performed manually can now be supported by modelling and simulation software, allowing engineers to assess performance before physical prototypes are produced. Computer-aided design and finite element analysis provide valuable insight into stress distribution, deflection and likely failure modes.
These tools are most effective when combined with manufacturing knowledge. Simulation can indicate how a spring should behave, but experience shows how materials respond during forming, stress relieving and heat treatment. Successful outcomes depend on aligning theory with practical production, ensuring designs perform as intended and remain consistent when manufactured at scale.
Material developments
Materials have evolved in parallel with these technologies. Earlier designs often relied on a relatively limited material range, with applications operating in less demanding conditions. Today’s environments are more challenging, requiring reliable performance under corrosion, temperature extremes, repeated loading and strict weight constraints.
In aerospace and defence, performance expectations are coupled with rigorous qualification processes. Oil and gas applications demand resistance to corrosive environments and high pressures, often in situations where maintenance access is limited. Space systems introduce vibration, thermal cycling and long operating lifetimes, while clean energy technologies place emphasis on weight and efficiency.
Material selection in these conditions is complex. It affects not only end performance but also manufacturability and consistency. A material that meets specification in theory may behave differently during production due to batch variation, surface condition or response to heat treatment. As a result, springmaking now sits firmly at the intersection of design engineering, materials science and manufacturing capability.
Fatigue performance has become a defining factor. In many applications, success is determined not by initial function but by how consistently a spring performs over time. Surface finish, residual stress and manufacturing methods all influence fatigue behaviour. Controlling these factors is now a central part of the engineering process.
Meeting standards
Inspection and measurement have undergone similar development. Where inspection was once viewed primarily as a final check, it is now integrated into production and quality management. Digital measurement systems allow data to be captured and linked directly to process parameters, supporting both control and compliance.
This shift reflects a broader change in customer expectations. It is no longer enough to confirm that a component meets specification. Many sectors require evidence to support that claim. Traceability, validation records and documented processes are now standard requirements, particularly in regulated industries.
Supply chains have become more transparent as a result. Customers expect visibility of material origins, process routes and inspection activity. Documentation supports audits, programme reviews and long-term support, forming an essential part of risk management.
Standards and approvals underpin this environment. At MSP, we operate to AS9100 and ISO 9001, with NADCAP accreditation for tensile testing and heat treatment. We also work within frameworks expected across regulated sectors, including JOSCAR, Cyber Essentials Plus and ITAR compliance, supported by systems aligned with relevant NIST requirements.
For energy applications, this also includes working to specified NACE standards where corrosion resistance and material suitability are critical. These frameworks help ensure that quality, security and traceability are embedded within day-to-day operations rather than treated as add-ons.
Engineering documentation has evolved alongside these expectations. Drawings that once contained limited detail now include defined tolerances, material specifications and inspection requirements. While this improves clarity, it can also introduce complexity if not handled carefully.
The most effective approach remains focused on function. Springs exist to deliver defined performance within an assembly, whether that relates to force, rate, fatigue life or operation within a temperature range. Clear understanding of that intent allows manufacturing processes and inspection strategies to focus on what matters most. As designs become more integrated and space-constrained, collaboration between designers and manufacturers has also increased. Early engagement can identify opportunities to improve consistency, simplify production and reduce validation risk without compromising performance.
Electrification, renewable energy and new transport systems are already driving demand for higher performance within tighter packaging constraints. Space, subsea and defence applications continue to require reliability under challenging conditions. In every case, the role of the spring remains unchanged, but the demands placed upon it continue to evolve.
People remain central to delivering those outcomes. Springmaking today requires a blend of practical skill and technical understanding. Programming, materials knowledge and quality management all play a role alongside traditional manufacturing expertise.
At MSP, apprenticeships and structured training help maintain that balance. Practical experience remains essential, but it is supported by formal systems designed to ensure knowledge is applied consistently. The focus is on preserving the fundamentals of the discipline while adapting to the demands of modern manufacturing.
Looking ahead, further progress is likely to come through integration and connectivity. Advances in data collection and process monitoring will continue to improve control and efficiency. At the same time, emerging technologies will keep raising expectations.
Adapting to rising expectations
The past 55 years show how springmaking has adapted to rising expectations. The discipline has become more precise, more measurable and more accountable, combining traditional knowledge with advanced technology and structured process control.
For Micro Spring & Presswork, that evolution has been ongoing since 1964. The business has developed the technical capability and systems required to support demanding industries while remaining focused on a simple objective: producing springs that perform reliably and consistently, exactly as intended. In modern engineering, that level of assurance is what turns a simple component into a critical part of a much larger system.
Authors: Neil Smith, business development manager; Michael Atkinson, dabs maker; and Neil Matthews, managing director, Micro Spring & Presswork (MSP).
Learn more: www.microspring.co.uk
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