Category: Engineering

Here at European Springs Ireland, when it comes to manufacturing wireforms, we’re proud to run one of the largest production machinery assemblies in Europe and have been doing so for decades. As well as our standard wireform elements, we offer bespoke options at unbeatable prices, making us the best choice for all your wireform needs.

No matter the industry you work in, or your needed number and configuration of wireforms, we’re certain to be able to help you, which is what we plan to do today. To help you understand more about these components, we’re taking a deep dive into everything you need to know about wireforms, how they’re made, and how you can use them. So read on to discover more about this fascinating product and what it can bring to your business.

What Are Wireforms?

Wireforms are small, intricate wire shapes used in various applications, from medical devices to automotive parts. They are typically made from wire bent or shaped into a specific form, and they can be manufactured into a wide range of shapes and sizes, materials, and finishes; for example, stainless steel, titanium, and nitinol.

These components are often used as part of larger assemblies or products and are found across a wide variety of industries, including:

• Medical
• Electronics
• Aerospace
• Automotive

At European Springs Ireland, we have manufactured wireforms for an extensive amount of different uses, such as:

• Headsets
• Computer brace devices
• Pins
• As part of our spring manufacturing processes

However, this isn’t an exhaustive list. The possibilities of wireform use are endless, and the configurations are only limited by the designers’ imaginations, which is why our experience manufacturing these components is vast and varied.

How Are Wireforms Used?

As mentioned, wireforms are incredibly versatile components used in an extensive range of industries. However, despite this, their importance is often overlooked, and they rarely get acknowledged for their impressively profound impact. As leading wireform manufacturers, we appreciate their influence and significance and want to express this to our clients. So, let’s take a more in-depth look into how they are used; you might be surprised just how many times you have come across wireforms without realising!

• Springs. One of the most common uses of wireforms is to manufacture springs, and as spring manufacturers, we’re well aware of their importance in this context. Wireforms can be designed to produce different types of springs, including compression springs and many other types we produce.
• Consumer products. Wireforms are used in everyday consumer products, such as toys and kitchen utensils. For example, wireforms can create a bicycle’s frame or make a wire whisk.
• Electrical contacts. A wireform can be bent into specific shapes to create the contact point of electrical switches, relays, and other devices.

Which Industries Need Wireforms?

Because of the vast range of applications for wireforms, the number of industries they are used in is extensive; let’s take a look.

• Automotive. Wireforms such as seat frames, exhaust hangers, and suspension components are used in automotive applications.
• Aerospace. These components could be landing gear components, engine parts, and control cables, for example.
• Medical. Surgical instruments, orthopaedic implants, and dental devices require wireforms.
• Industrial manufacturing. Wireforms are used in various industrial manufacturing applications, such as machinery components, conveyor systems, and safety guards.
• Agriculture. We work closely with agriculture industry professionals, providing precision wireforms for fencing, livestock handling equipment, and irrigation systems.

These are just a few examples of industries that use wireforms. In general, any industry that requires precision metal components may use wireforms in some capacity, which is why they’re one of our most popular products.

How Are Wireforms Manufactured?

As mentioned, we stock standard configurations of wireforms but also offer bespoke and custom products for those who need something more specific to meet their needs. In fact, we can produce wireforms in virtually any design you can imagine, thanks to our use of 14 cutting-edge CNC automated spring coilers and related equipment. This advanced machinery allows us to manufacture these bespoke wireforms in large quantities, so if you’re interested in bulk ordering, don’t worry; quality will not be compromised, and each component will be perfect.

Alternatively, we still rely on handcrafted wire pins for relatively small orders, which requires our expert spring manufacturers to have an exceptional eye for detail and impressive precision. With this extensive experience and skill in spring wire properties, we are able to produce wire pins of exceptional precision and quality, no matter the size of the order or the required configurations. We can produce wires ranging from 0.20mm to 6.0mm in diameter and create wireforms that will conform to any pattern you envision. These patterns can include pins, three-dimensional shapes, locking clips, and other designs; as mentioned, the only limit is the designers’ imagination.

If this is something you’re interested in, or you’d like to learn more about the wireform processes here at European Springs Ireland, we’d like to hear from you. Please contact our team today to enquire about ordering or to discuss your options with our expert team.

Here at European Springs Ireland, we are dedicated to encouraging young people to join the fascinating field of spring manufacturing. As it is such a broad sector, we believe that anyone can find their place within engineering, which is why we’re always on the lookout for driven individuals to join our team through our apprenticeship programs.

We want everyone to feel comfortable and happy in their role, so today, we’re looking into whether an engineering apprenticeship could be right for you. Read on to learn more about what we offer and take the first steps in your new career.

What Will I Learn During An Engineering Apprenticeship?

During your engineering apprenticeship, you will learn various technical and practical skills related to your specific field. The exact curriculum will depend on the type of engineering apprenticeship you are undertaking, as well as your employer’s requirements and the regulatory body overseeing the program.

For example, if you choose to do a spring manufacturing apprenticeship with European Springs Ireland, you will learn the following:

• Technical knowledge. You’ll learn about the fundamental principles of spring engineering, including maths, physics, mechanics, and our specific spring manufacturing technology and equipment.
• Practical skills. You will have the opportunity to apply technical knowledge in a practical setting, working on projects and tasks under the guidance of experienced engineers.
• Safety procedures. You will learn about the various safety procedures and protocols necessary to maintain a safe working environment when manufacturing springs.
• Communication and teamwork. You will learn to communicate effectively with other students studying engineering apprenticeships and those tutoring you.

This is not an exhaustive list of everything you’ll learn while studying for your engineering apprenticeship. There are countless other things you will pick up while learning, such as valuable advice from those who have been working in the industry for a long time. This experience provides the foundational knowledge and skills necessary to succeed in your chosen field.

How Will I Learn and Be Assessed During My Engineering Apprenticeship?

You will likely learn through a combination of on-the-job training and classroom-based instruction. The exact balance of these two types of learning will depend on the specific requirements of your apprenticeship, as each program is different.

On-the-job training will typically involve working under the guidance of our experienced spring engineers, completing practical tasks and projects, and learning from real-world scenarios. You may be assigned to work on various projects, with increasing levels of responsibility as you progress through your apprenticeship.

Classroom-based instruction may take the form of lectures, seminars, and workshops. These sessions will provide you with the theoretical knowledge and technical skills necessary to succeed in your field, as well as an understanding of industry standards and best practices.

Assessment during your engineering apprenticeship will typically be carried out through coursework, practical assessments, and exams. Your progress will be monitored and evaluated throughout your apprenticeship, with feedback provided on your strengths and areas for improvement. You must demonstrate your understanding of key concepts and ability to apply them in practical scenarios to complete your apprenticeship successfully.

Advantages of Engineering Apprenticeships

There are several advantages to pursuing an engineering apprenticeship, such as:

• Hands-on learning and a unique opportunity to gain classroom knowledge and experience real-world projects at the same time.
• Engineering apprenticeships are designed to prepare you for a career and succeed in your profession.
• Whether manufacturing compression springs or managing a bulk order project, you will constantly network with fellow apprentices, mentors, and industry experts, allowing you to build valuable connections.
• Earn while you learn! Of course, one of the greatest advantages for young people undertaking an apprenticeship is the opportunity to earn money while gaining valuable experience and knowledge.
• Completing an engineering apprenticeship can lead to professional certification, which is highly valued by employers and helps you stand out in a competitive job market.

Disadvantages of Engineering Apprenticeships

We understand that engineering apprenticeships aren’t for everybody, and there are several reasons why it may not be the right path for you.

For example, you should only choose an apprenticeship if you’re sure about the field in which you’d like to work. This is because apprenticeships provide a direct route to specific career paths, making you desirable to employers within the industry. However, if you begin your course and realise the sector you’re in isn’t for you, you may need to reconsider completing the apprenticeship.

In addition, some apprentices are discouraged by their starting wages. Although it may be lower than you wish, you must understand that once qualified, your apprenticeship will set you up for a fruitful career. In addition, no other students can say they’re earning while learning, so it’s important to remember that the money you’re making is much better than if you were attending university.

Where Can An Engineering Apprenticeship Take Me?

An engineering apprenticeship can lead to many exciting career paths in a variety of industries. In addition, the skills and knowledge gained prepare you for a wide range of jobs depending on the focus of your apprenticeship.

For example, here are a few of the most common routes an engineering apprentice could go down once qualified:

• Design engineer, focusing on creating new products
• Maintenance engineer, ensuring all equipment is functioning properly
• Project manager, overseeing and coordinating engineering projects
• Manufacturing engineer, focusing on the design and optimisation of production processes
• Quality control engineer, working to ensure products and systems meet the required quality standards

In addition, many of our apprentices have gone on to have successful careers working at European Springs Irelands for many years, making their way up the company in their chosen directions.

If this sounds like the right career path for you, we’d love to hear from you. So please contact us today and start your journey.

Here at European Springs Ireland, we’re committed to providing our customers with a smooth journey while working with us to ensure they get everything they need. From initial conversations to providing repairs and maintenance long after handing over their orders, we’re here for our customers. One of the ways we assist is through our design support, which we’re exploring in today’s blog post.

We’re taking a look at the design support you should expect to receive when working with our team and what this entails, including our processes and how we handle each order, from mass productions to one-offs.

What Is Design Support?

Design support is part of our spring manufacturing process. It refers to the assistance provided to customers in designing custom springs, pressings, and wireforms that meet their specific needs and requirements. This support can include a range of services, such as consultation on material selection, wire diameter, spring rate, and other design parameters. For example, design support aims to help customers create a spring optimised for their application, considering load capacity, deflection, frequency, and durability factors. This can lead to improved performance, longer service life, and reduced costs for the customer over the long term. In addition, our conversations help bring our customers’ products to life, allowing them to visualise what they’re ordering and understand how it will function. This also allows our customers to voice any necessary adjustments to the design before production begins.

Our Design Support Process

As leading spring manufacturers in Ireland with over 70 years of industry experience, we are proud of our design support process and believe we have perfected this service.

Our expert team of engineers assist you in making decisions on the design of your product, whether you have a bulk order of compression springs or a single pressing. No matter the size of your order, we can help you decide on the design, material, and surface treatment of your chosen pressings, stampings, or springs. We do this to ensure customers get the most suitable products for their application and are completely satisfied with the final result.

Each order goes through our rigorous process, which involves the following:

• Selecting the material and considering technical requirements, price, and availability
• Manufacturing method
• Capital investment for tooling
• Finishing requirements, such as heat treatment
• Assembly requirements, including automation
• Repeatability

These requirements are essential in manufacturing the perfect product for our customers. They help us pinpoint exactly what our customers require, so they leave us satisfied and confident in our services. It also ensures that everyone involved in the manufacturing process is clear on the goals and that there aren’t any confusions or backtracking that could cost us and our customers time, money, and other resources.

Custom Spring, Pressing, and Wireform Manufacturing and Your Valuable Input

Our customers’ input is crucial when it comes to bespoke spring design for several reasons, such as:

• Ensuring we meet their specific requirements. Each custom product has unique requirements, such as dimensions, materials, and load-bearing capacities, so it’s vital that everyone involved in the manufacture understands this.
• Customisation. We pride ourselves on our bespoke services, meaning our spring design team can provide truly unique and specifically tailored products, and our client’s input on these details is essential.

• Building trust. Taking the clients’ input into account can also help build trust between the manufacturer and the client. By working collaboratively and considering the client’s needs, manufacturers can demonstrate their commitment to providing high-quality, customised products that meet their needs.

Design Support for Bulk and One-Off Orders

As mentioned, we offer design support for all orders, no matter how big or small. However, there are slight differences between the process if you want a bulk order or a one-off product.

Of course, the main difference between bulk and one-off orders is the number of products produced. This means more materials, time, and other resources will be used during the production of bulk orders, making it absolutely vital that everyone is satisfied with the final design before production begins. However, if a customer requests a single product, although the design is still important, it won’t have a catastrophic effect if slight changes are needed to the product after its production.

Following this, although some may believe that the design process may be lengthier for bulk orders, this isn’t always true. Although they require a lot of detail from the customer to ensure complete satisfaction before production begins, customers will bulk order our standard products, such as our tension springs, for example. In contrast, one-off orders may have unique and incredibly specific requirements that aren’t included in our Spring Catalogue.

Whatever your order, our design support team needs your input to ensure we provide you with the right product. So please get in touch today to begin those all-important conversations with our spring design experts.

As technology creeps further into every aspect of the manufacturing industry, European Springs Ireland is excited to be at the forefront of technological developments. We’re fascinated by the successes of these innovations and are always looking for ways we can implement new technology into our practices to provide better services for our clients.

One technological advancement that has proved it is here to stay is automation. In recent years, we have seen incredible automation developments in manufacturing and have been fascinated by how it is assisting manufacturers and engineers worldwide.

So, today, we’re exploring everything you need to know about automation in manufacturing. We’re taking you on an insightful look behind the curtain as we delve into what it is, how it has been implemented into the industry, and what the pros and cons are of this revolutionary technology; read on to learn more.

What Is Automation?

Automation is a term for any technology or computerised machine that, in order for it to work, requires little human input. While automation isn’t new, the different types of automated technology available today are constantly updated with the latest software.

There are different types of automation available, for example:

• AI. Artificial intelligence is used in many manufacturing companies across the world. For example, in spring manufacturing, it can be used in the replacement of the testing process to minimise resource waste.
• Process automation. This involves the use of apps or other software used to streamline business processes that were previously completed by humans either on a computer or through paperwork.
• Robotics. Also known as integration automation, robots have been used to mimic the actions of a human and can complete physical tasks such as packing.

There are also other, much more basic examples of automation that aren’t just found within the manufacturing industry. For example, using an online chat room for employees is considered a part of automation, as it replaces physical human interactions, which has been implemented in almost all industries.

How Has Automation Been Implemented Into Manufacturing?

As mentioned, automation has been implemented in the manufacturing industry in a wide variety of ways, such as through:

• Robotic assembly lines
• Computer-controlled tools
• Automated material handling
• Automated inspection systems

These are just a few examples of the many different areas of automated manufacturing, and we believe it will only get bigger and better. Whilst we would never expect automation to take over the creative minds of our spring design team, for example, we do believe it can be beneficial in other areas of our business. For instance, when it comes to producing custom bulk orders for our clients, implementing automotive technology may increase the springs’ accuracy and speed up the process.

Automation and Analytics

Analytics are used throughout manufacturing and has been a major part of Industry 4.0 in terms of machine data. As this often involves a lot of technical skill and, more often than not, advanced experience, automation has been tested to take over this area of manufacturing.

The two work together by providing automated data on production processes and machines. The automation systems are able to collect data from machines before feeding it into analytics software for review. During the review, the collected data can be used to identify patterns, which then allows manufacturers to make informed decisions about improving productivity and efficiency, for example. In addition, automation systems can also use this data to predict problems with the machines and prevent them from occurring.

Advantages of Automation in Manufacturing

There are plenty of advantages of automation in manufacturing; let’s take a look:

• Increased efficiency. Automation reduces production time significantly and works to streamline processes.
• Reduces human error. It can eliminate mistakes made by humans and produce more consistent products.
• Cost-effective in the long-term. By increasing production rates and reducing labour costs, automation can help manufacturing companies cut costs in the long run.
• Increased safety. By eliminating human error, injuries are reduced. In addition, as mentioned, automation processes can predict when a machine may have a problem, improving the safety of the technology humans work with.

Disadvantages of Automation in Manufacturing

Of course, many people will have doubts about automation, which is completely understandable. While it is impressive technology, it also comes with some drawbacks.

• Potential job losses. As mentioned, we don’t believe automation could take over humans in all aspects of manufacturing. Still, some areas may see some workforce cuts due to the overwhelming advantages of automation.
• High initial investment. Automation is cost-effective in the long term, but it must be mentioned that the initial investments can be high. Machinery, software, and other equipment are expensive.
• Technical issues. Like all technology, automation may run into some technical issues or malfunctions, which can cause delays in productivity.

Whatever your feeling about automation area, there is no denying that it is making its way into manufacturing in a variety of forms. If you work in the sector, you probably already noticed an increase in automation; if not, you certainly will now.

As mentioned, we’re excited about these digital transformations here at European Springs Ireland and actively seek opportunities to implement them into our spring manufacturing processes.

If you’re as excited as us by digital change and think that the fascinating world of spring design and manufacturing is a place you would thrive, we would like to hear from you. Get in touch to find out about our latest vacancies and start your new career at this exciting time of automation transformation.

At European Springs, we are proud of our role in manufacturing high-quality springs and pressings for a broad range of applications. We strive to develop new innovative processes and methods to maintain our status as one of the UK’s top manufacturers. Part of our work is to understand the causes of spring failure and prevent any such losses from occurring in our products with superior techniques.

Spring Design Considerations

With so many applications that require some spring to function, spring failure at any time will be at best a hindrance and, at worst disastrous. As spring manufacturers in Ireland, we understand that spring failure is not an option. However, we believe that by understanding why a spring fails, you can work toward avoiding it for yourself.

Spring Stress is a primary cause of spring failure. Overstessing your spring by applying stress or force that exceeds its specifications indicates a breakdown in the design process. For example, an extension spring will not have much elasticity if designed for strength, so by overextending this spring, you will put it under extreme stress, and it will most likely break.

Wrong Material Choice is also a common cause of spring failure. With so many materials available for your spring manufacture, you need to be sure that you select the best material for the function it needs to perform adequately. For example, Stainless steel is a good choice for clock springs but may not be for other spring types such as valve springs.

Shock loading and other misuses of your spring will lead to spring failure. Shock loading is when the weight of the load increases suddenly or speeds up. Dropping your spring from a significant height is an example of accidental shock loading. The more times the spring is shock loaded, the higher the risk of failure. You can mitigate this with friction devices such as vibration dampening devices or internal damper coils.

The key to our spring manufacturing process is to source specific high-quality materials to meet even the most exacting of production standards. Combined with our in-house contemporary CAD and CAM software and systems, we can help realise a comprehensive range of prototype ideas so you can be sure your specification will work in your required application.

Preserving Your Springs

Even with the best materials, manufacture and design, no spring will last forever; fortunately, as experienced gas spring manufacturers, we know of ways you can increase your spring’s life and prolong replacing it for as long as possible.

Several factors can shorten your spring’s lifetime, but you can ensure your product lasts longer than you expect with careful planning and a reputable manufacturer.

Friction – A spring touching the sides of a shaft (for example, a compression spring inside a gas spring), with repeated friction, will cause increasing damage to both components until one fails.

Environment – A spring that doesn’t have the correct finish will be less likely to function. It will continue to degrade until it fails. In addition, heat or extreme humidity will negatively affect an untreated spring and potentially cause spring relaxation. By keeping these springs cool, you can prolong the life of your spring and reduce the chance of spring relaxation

Stress – This is linked to the overstressing mentioned above. Applying too much pressure to your spring is unlikely to compress as far as it is designed. This will lead to overstressing and breaks. We recommend choosing a larger wire diameter to reduce the chance of spring stress. Additionally, lowering the final load and allowing more room for the spring will enhance longevity.

Prestressing to Prevent Spring Failure

Prestressing is the process where the spring is loaded to the point where the wire is under controlled stress. A spring designed to be prestressed will benefit from withstanding higher pressures and increasing its load-carrying ability while lighter than its equivalents. When spring is prestressed, the changes will increase its lifetime and provide you with a better product.

Shot Peening Improving Operating Life

Shot peening is a method where the surface of the spring is hit with small spheres. It is used on clutch springs, coil springs and compression springs. These impacts will create small indentations, which will overlap as they are repeatedly struck. As a result, the whole exterior of your spring will have a layer of metal in a state of increased residual compressive density. Shot peening essentially increases the tensile strength of your material and makes it far harder for fatigue cracks to start to form. Shot peening is beneficial for:

• Preventing corrosion
• Cracks and fatigue
• Hydrogen embrittlement

High-Quality Bespoke Spring and Pressings from European Springs

By choosing a world-renowned gas spring manufacturer such as European Springs, you can be confident that your required springs will be the highest quality choice with high durability and customised for whatever you need them for.

If you’re interested in any springs, pressings or wireforms, then please browse our stock catalogue to see what we have readily available.