Category: Engineering

There’s a lot to consider when bringing your spring and pressing designs to life, and it can be overwhelming if you’re not too familiar with the design process. Translating your vision and needs into a tangible product can be daunting without the proper tools and techniques, which is why prototyping exists.

Prototyping is an invaluable resource for designers looking to refine their ideas and create a successful product. So, from choosing the right materials and tools to refining your designs, we will guide you through the prototyping process and show you how to create a functional and aesthetically pleasing product with the help of our expert designers and engineers. Let’s dive in and discover the power of prototyping in creating exceptional spring, pressing, and wireform designs.

What Is Prototyping?

Prototyping is the process of creating a preliminary version or model of a product, design, or system to test and refine its functionality and design. It can be used in a wide range of industries, from product design and engineering to software development and user experience design.

The purpose of prototyping is to identify any flaws, errors, or limitations in the design and functionality of a product or system and to make necessary adjustments before it is finalised and launched. The prototyping process can involve creating physical models, 3D printed objects, wireframes, or even virtual simulations. Through prototyping, designers and developers can refine and improve their ideas, resulting in a more polished and successful final product.

The Importance of Prototyping

In terms of design, prototyping plays a crucial role as it allows our engineers and designers to test and refine their ideas before moving to production. For example, springs are used in various industries, including automotive, aerospace, medical, and consumer electronics, among many others, so, rapidly prototyping and testing new designs can help companies like ourselves reduce time to market, improve product quality, and lower development costs. Here are some of the key benefits of prototyping in both the design of springs, pressings, and wireforms:

• Testing Functionality. Prototyping allows designers to test the functionality of a spring design and identify any potential issues or areas of improvement. This can help ensure the final product meets the necessary performance requirements and can operate reliably over its expected lifespan.
• Material Selection. Prototyping allows designers to test different materials and evaluate their performance under different conditions, such as temperature and load. For example, pressings involve shaping a flat sheet of material into a desired form through processes like stamping or deep drawing. The material’s formability determines how easily it can be shaped without cracking or tearing. Some materials, such as aluminum or certain grades of steel, exhibit excellent formability, making them suitable for complex pressings and the prototype can help determine this.
• Customisation. The prototyping process can be used to create bespoke springs tailored to specific applications or customer needs, such as ours here at European Springs Ireland.
• Cost Optimisation. Prototyping can also help identify opportunities to optimise a wireform design for cost reduction, for example. By reducing the amount of material used or simplifying the manufacturing process, we can create a cost-effective wireform that meets your needs.

Overall, prototyping is a critical step in the design process that enables engineers and designers to refine their designs and ensure that the final product meets the necessary performance requirements. By testing different materials, shapes, and sizes, we can create custom springs, pressings, or wireforms optimised for their specific application and reduce the risk of expensive design errors or manufacturing defects.

Types of Prototypes

Several types of prototypes can be used in spring, pressing, and wirefoem design, depending on the specific application and requirements; let’s take a look.

• Proof of concept prototype. This is used to test the basic functionality of the design. It may be made from simple, low-cost material like plastic or wire and is used to ensure the spring, pressing, or wireform will function as intended.
• Functional prototype. This is used to test the performance of the design under real-world conditions and is often made from more durable materials like metal. It may be tested for strength, durability, and fatigue resistance.
• Appearance prototype. This type of prototype is used to test the aesthetic qualities of the compression spring design, for example, such as its shape, colour, and finish. It may be made from various materials, including plastic, metal, or even 3D printed materials, and is used to evaluate the design’s visual appeal.
• Engineering prototype. These prototypes are used to test the design’s manufacturability and ease of assembly. Typically, it is made from the same materials used in the final product to ensure that the design can be efficiently manufactured and assembled. For example, a bespoke metal pressing will be manufactured from the desired metal,
• Pre-production prototype. This is used to test the design’s performance in large-scale production runs. It is made using the same manufacturing processes used for the final product and is used to identify any potential manufacturing issues that may arise during production.

The kind of prototype utilised in the design will vary based on the distinct needs of the application and the phase of the process, and our expert designers and manufacturers will use the appropriate method depending on your needs.

Prototyping at European Springs Ireland

Our Engineering and Production facility can provide quick prototyping services, utilising techniques like Laser Cut/Chemically Etched Blanks or simple Blanking Tools. For forming, we use standard tooling that offers a cost-effective solution for situations where the final part design has not yet been established or for low-volume parts where tooling investment is unnecessary.

Whether you need a one-off prototype or low-volume parts for testing purposes, we are fully equipped to meet your requirements.

Please don’t hesitate to contact our team to find out more about what we can offer you so you can get the most out of your springs, pressings, or wireforms.

Here at European Springs, we are leading manufacturers of springs and metal components in Ireland, and with over 70 years of experience in the industry, we have established a reputation for producing high-quality, reliable products that meet the needs of a wide range of customers.

This long list of products includes stampings and pressings, which have a wide range of uses and help those in an extensive range of industries. So today, we’re exploring everything from the basics of stampings and pressings to their various applications, advantages, and design considerations. Let’s dive in and discover everything you need to know about our stampings and pressings.

What Are Stampings and Pressings?

Pressings and stampings are metal components produced through different manufacturing processes but share many similarities. Both processes involve manipulating a flat metal sheet into a specific shape using a tool and die set.

For example, pressings involve applying force to a metal sheet or strip using a press, while stampings involve pressing a flat sheet of metal into a specific shape using a stamping press. The resulting components can vary in complexity and size, from simple brackets to intricate parts used in electronics and aerospace applications.

We produce our versatile and cost-effective pressings and stampings using various materials, including stainless steel, brass, copper, and aluminium, to meet the needs of a diverse range of industries.

Types of Stampings and Pressings

We manufacture many different stampings and pressings here at European Springs, each with unique characteristics and applications; let’s take a look:

• Flat stampings. These stampings are flat metal components cut and formed into various shapes using a stamping press.
• Progressive stampings. Progressive stampings involve multiple stations within a single die to create more complex shapes and features, typically used for higher-volume production.
• Deep-drawn stampings. These are created by pulling a flat metal sheet into a three-dimensional shape using a series of dies. Deep-drawn stampings are often used for creating cylindrical or dome-shaped components.
• Transfer stampings. Transfer stampings are similar to progressive stampings but involve moving the material between multiple dies to create more complex shapes.
• Fine blanking. Fine blanking is a specialised form of stamping that involves using high-tonnage presses and specialised tooling to produce parts with extremely tight tolerances and smooth edges.
• Four slide stampings. Four slide stampings are created using a specialised machine that bends and shapes the metal using tooling with 360-degree capability. These types of stampings can save on material utilisation.

Of course, in addition to these, there are many other types of stampings and pressings, each with unique benefits and applications. If you’re unsure of which type you need for your application, our expert stamping and pressing engineers can assess and produce exactly what is required, so rest assured that you’ll receive a product that works for you.

The Materials We Use for Stampings and Pressings

Our dedicated and passionate Design Support team do everything they can to ensure you receive a product that is refined and developed before production even begins, which includes deciding on the perfect material. This way, we have taken great care to consider any specific requirements you might have and thus produce a product that is exactly what you need.

We create each pressing and stamping from a high-quality metal strip material such as:

• Aluminium
• Beryllium copper
• Brass
• Carbon spring steel
• Copper
• Phosphor bronze
• Stainless steel
• Super alloy

In addition, we also use both flattened wire and even non-metallic materials to give you as much choice as we possibly can. The material used in a stamping or pressing can significantly impact its performance and properties, so the material chosen must be the right fit for your stamping or pressing’s application. For example, some materials are more resistant to corrosion than others, so materials such as stainless steel or aluminium may be preferred in applications where corrosion is a concern. Similarly, materials such as copper or aluminium are highly conductive and may be the best choice in applications where electrical conductivity is important.

The Manufacturing Process

Our comprehensive stamping and pressing manufacturing process allows us to produce high-quality components to meet the needs of our customers. For example, we work closely with each customer to understand their unique requirements and develop 2D and 3D CAD designs for the stamped or pressed component. Once the design is finalised, we move on to tooling design and manufacture, where our experienced toolmakers use state-of-the-art machinery to create the necessary tooling and dies to produce the component.

With the tooling in place, we begin the stamping and pressing process. Our skilled operators use hydraulic and mechanical presses to produce the component to the required specifications before the finishing stage. Depending on the products’ needs, this can include powder coating, plating, painting, and much more.

With our experienced engineers, skilled operators, and state-of-the-art machinery, we can produce a wide range of stampings and pressings to meet any requirement.

Quality Control

We have a rigorous quality control system throughout manufacturing to ensure the component meets the required specifications. We use various measuring and testing equipment to verify the component’s dimensions, strength, and other properties.

Quality control is a crucial step in the stamping and pressing manufacturing process at European Springs Ireland. We conduct quality control checks at each stage of the manufacturing process to ensure that any issues are identified and addressed early. For example, we may use coordinate measuring machines (CMMs) to verify the dimensions of the component or tensile testing machines to test its strength and durability.

In addition to the equipment we use, we also have a team of experienced quality control personnel trained to identify any issues or defects. They work closely with our engineers and operators to ensure the component meets all the requirements.

So, if you’re interested in our stampings and pressings and would either like to learn more about the process or enquire about an order, please don’t hesitate to get in touch, and a member of our team will be more than happy to assist.

The manufacturing industry has been a vital part of the global economy for centuries, and as technology continues to advance rapidly, it has become increasingly important for the manufacturing industry to adapt and embrace new technologies.

One way to ensure that the industry stays up-to-date is through apprenticeships. Apprenticeship schemes are an excellent way for individuals to gain the skills and knowledge they need to excel in the manufacturing sector. And at the same time, assist the wider industry in developing further.

So, as providers of manufacturing apprenticeships in Ireland, we wanted to provide a professional opinion on what the future holds for these schemes and how we’re adapting to industry changes.

A Brief History of Manufacturing Apprenticeships

Apprenticeships have been used to train skilled workers in various trades for thousands of years. In fact, the concept of apprenticeships dates back to the Middle Ages, when young people would enter into an agreement with a master craftsman to learn a trade. However, it wasn’t until the Industrial Revolution in the 18th and 19th centuries apprenticeships became even more important as new manufacturing techniques, and machinery were developed. In the early 20th century, the concept of apprenticeships became more formalised and standardised and then during World War II, apprenticeships were used extensively in the manufacturing industry to train workers for the war effort. After the war, apprenticeships continued to train workers for the manufacturing industry and other trades such as plumbing, electrical work, and carpentry, which brings us to today.

Now, manufacturing apprenticeships are used to encourage young people to start a STEM career and are viewed as an effective alternative to university. As a result, they’re an incredibly popular path for those interested in joining the manufacturing industry, and we’re very proud to be contributing to this field.

Here at European Springs Ireland, we’re always on the lookout for ways to improve our apprenticeship offerings in line with industry-wide changes, which means looking to the future.

Industry 4.0

Industry 4.0 is the fourth industrial revolution, integrating advanced technologies such as the Internet of Things (IoT), artificial intelligence (AI), robotics, and big data analytics into manufacturing. The impact of Industry 4.0 on the future of manufacturing apprenticeships is significant. With the adoption of advanced technologies, manufacturing companies will require a new set of skills from their workforce, and apprenticeships will need to adapt to keep up with these changes. For example, apprenticeship schemes must focus on digital skills, such as programming, data analysis, and robotics, to ensure the workforce can effectively operate and maintain the new technologies integrated into the manufacturing process. In addition, Industry 4.0 will also impact the delivery of apprenticeships as digital platforms and e-learning become more common in training programs. This shift towards digital delivery will enable apprentices to learn at their own pace and access training materials remotely, increasing accessibility and flexibility.

Changing Demographics

The changing demographics in society significantly impact the future of manufacturing apprenticeships in several ways. For example, as the baby boomer generation reaches retirement age, there is a significant shortage of skilled workers in the manufacturing industry, increasing demand for apprenticeships to train the next generation.

In addition, the demographics of the workforce are changing, with more people of colour, individuals from underrepresented communities, and female apprentices entering the industry. This increased diversity has led to a need for apprenticeships that can cater to the needs of these different groups.

To address these changes, manufacturers are developing new apprenticeship programs that are more inclusive and flexible. And ultimately, the success of these efforts will depend on the ability of the industry to adapt to changing demographics and to provide the training and support that workers need to succeed.

Addressing the Skills Gap

Manufacturers are taking a variety of steps to address the skills gap and support the future of manufacturing apprenticeships, such as:

• Partnering with educational institutions. Manufacturers are partnering with high schools, colleges, and universities to develop educational programs that align with the skills needed in their industry.
• Investing in technology. The manufacturing industry is becoming increasingly technologically advanced, so manufacturers are investing in technology to help their employees keep up with these changes. This includes investing in automation, artificial intelligence monitoring, and other technologies that will help workers be more efficient and effective in their jobs.
• Supporting diversity and inclusion. For example, manufacturers are working to create a more diverse and inclusive workforce by recruiting more women to close the gender skills gap.

By investing in education, technology, and workforce development programs, manufacturers are helping to ensure that the industry has the skilled workers it needs to thrive in the years ahead.

Hybrid Learning

Like most other industries, hybrid learning and working are firmly set in the future of manufacturing apprenticeships. It combines traditional in-person classroom instruction with online learning, allowing apprentices to learn at their own pace and on their own schedule. This provides students with increased flexibility, which is particularly beneficial for those working full-time jobs or having other responsibilities outside their apprenticeship.

Additionally, hybrid learning provides apprentices access to a wider range of learning resources than traditional classroom instruction alone. These resources can include videos, webinars, podcasts, and other online content to enhance the learning experience.

Overall, hybrid learning is transforming the future of manufacturing apprenticeships, and manufacturers are increasingly adopting hybrid learning models to help their apprentices gain the skills they need to succeed in the manufacturing industry.

So, if you’re interested in joining this ever-changing industry, we’d love to hear from you. Now is the time to invest in your future and choose European Springs Ireland to kickstart your career in manufacturing. We offer excellent apprenticeship schemes where you’ll learn valuable skills and experience in manufacturing compression springs, designing bespoke pressings, and more. So, get in touch today, and a member of our team will be delighted to point you in the right direction.

Springs are essential in many industries and play a critical role in the functions of a wide range of products, machinery, and equipment. From automotive to medical, springs are used in various applications for an extensive list of different industries. Here at European Springs Ireland, our experience working with these industries is vast, and no day is ever the same, making it an incredibly exciting place to work.

So, to highlight this and provide insight into our varying work, we’re exploring the different industries that rely on spring manufacturers in this blog. We’re delving into the different sectors and types of springs used in their equipment and machinery, so keep reading to get a behind-the-curtain look at the importance of what we do.

Agriculture

We work closely with companies in the agriculture industry, providing springs for grassland harvesting machinery. These components are crucial for agricultural machines, for example, suspension springs. Tractors, ploughs, and other heavy agricultural machinery rely on suspension systems to absorb the shock and vibration from operating in uneven terrain. High-quality suspension springs are necessary to ensure these machines operate smoothly and efficiently. Without reliable suspension springs, those in the agriculture industry would experience breakdowns in their tractors and other machinery, which could have a detrimental effect on their work and cause delays down the supply chain.

As a reliable spring manufacturer with high quality at the forefront of our products, we ensure that our customers in the agriculture industry have the springs they need to get on with their work without worrying about breakdowns and damage to their machinery.

Automotive

At European Springs Ireland, we have found that our products have the most extensive application in the automotive sector. Not surprisingly, torsion springs are used most frequently throughout the industry due to their rotational movement. For example, they’re used in several components of an engine, such as camshafts, crankshafts, and timing belt tensioners. These springs ensure the engine operates smoothly and efficiently by maintaining the correct timing and tension.

In addition, much like in the agriculture industry, suspension springs are used throughout the automotive sector. Suspension systems in cars, trucks and other vehicles require these springs to absorb shock and provide a smooth ride.

Construction

Construction is an incredibly broad industry, meaning there are countless ways that they rely on spring manufacturers, such as ourselves, to provide essential components. For example, door hinges use compression springs to provide tension and help keep the door closed. This means builders will need high-quality, reliable compression springs to complete their door constructions and finish a job to the best standard.

Similarly, different types of springs are used during bridge construction to help absorb shock and movement caused by wind or heavy traffic. These springs are often placed in the bridge’s foundation or support structures, making them key components in the overall structure of the bridge.

Defence and Aerospace

European Springs Ireland is responsible for supplying the defence industry with a variety of springs and wireforms, and we frequently manufacture springs used in aerospace applications. This includes creating springs for next-generation airborne smart decoys, high-spec electrical connectors, and even the Eurofighter.

We understand the crucial role that high-quality functional components play in ensuring precision and safety, and with the help of our skilled technicians and state-of-the-art CNC equipment, we’re able to craft custom designs and unique military spring components. This includes aerospace springs and magazine springs.

Electronics

As the electronics industry is so broad, several types of springs are used in the sector for various purposes; let’s take a look.

• Compression springs. These are the most commonly used springs in the electronics industry and are used as battery contacts, switch contacts and connectors.
• Torsion springs. Torsion springs are chosen when a rotational force is required, such as in relays and switches.
• Wave springs. These springs are used in applications where space is limited, such as microelectronic devices.
• Constant force springs. A constant force is needed in tape and reel applications, making these springs the best choice.

Overall, the type of spring used in the electronics industry will depend on the specific application and requirements of the product, but we are able to manufacture any configuration you require.

Medical

Finally, we’re exploring how our medical industry uses our springs. Fascinatingly, different spring types are used in various implants, such as dental implants, to support and stabilise the affected area.

In addition, they are also used in medical devices, such as infusion pumps, insulin pens, and inhalers, providing accurate and precise dosing of medication.

As you can see, our experience is hugely varied, and working with so many different businesses from a variety of industries allows us to constantly expand and perfect our offerings. As a result, no day is ever the same, and we’re always looking for new and interesting uses for our springs.

So, if you’re looking for a reliable spring manufacturer in Ireland, we want to hear from you. Contact us today, and a member of our expert team will be more than happy to help.