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FEATURE


SPRINGS & SHOCK ABSORBERS


55thanniverSary The arT of conTrolled


For Design Solutions’ 55th anniversary, we trace how springmaking has evolved from a skilled manufacturing craft into a tightly controlled engineering discipline. By Neil Smith, business


development manager; Michael Atkinson, dabs maker; and Neil Matthews, managing director, Micro Spring & Presswork (MSP)


Hands-on expertise has always been


important in springmaking 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. 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.


2 DeSiGn SOLUtiOnS 1971-2026 JULY/AUGUST 2026 2


The iMporTance of hands-on experTise 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


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