Small springs, miniature springs, and micro wireforms may only seem like minor parts in the grand scheme of things, but their design and performance are critical to the performance and reliability of exceptionally complex end products – including critical medical devices and aerospace components.
The question many engineers and procurement teams face: should you use an off-the-shelf spring, or invest in a custom solution? At HyTech Spring & Machine, we’ve seen countless real-world examples of precision applications that benefit from custom springs – whether in terms of fitment, functional performance, or end product reliability.
The Limitations of Off-the-Shelf (OTS) Springs
Commercial off-the-shelf (COTS) springs are often the more attractive option with a lower up-front cost and immediate availability. However, depending on the end application, there can be some significant tradeoffs to keep in mind:
- Compromised Fit – OTS parts rarely match exact specifications. They can force design changes or introduce mechanical inefficiencies that reduce product performance or longevity.
- Material Mismatch – Standard springs may not be available in the optimal material for your application, risking issues like corrosion, fatigue, or conductivity failure.
- Limited Functionality – Pre-made parts are built for general use, not tailored loads, stroke lengths, or space constraints.
- Quality Variability – OTS components often lack the traceability or consistency required for critical or regulated applications.
The Case for Custom Springs – Five Advantages vs. Commercial Off-the-Shelf Options
1. Precision Fit and Functional Performance
Custom springs are designed for your exact dimensions, load requirements, and constraints. This ensures optimal performance without compromising other aspects of your product. At HyTech, we specialize in miniature and micro spring designs down to wire diameters as small as .001”. Our engineering team collaborates closely with customers to tailor every spring and wireform for specific motion, force, or assembly challenges.
2. Optimized Material Selection
HyTech offers a broad range of spring materials, from standard carbon and stainless steels to exotic alloys like Elgiloy®, Inconel®, and MP35N®. We help you choose the best material based on mechanical properties, environmental exposure, and regulatory compliance – optimizing for corrosion resistance, fatigue life, and biocompatibility where needed.
3. Reduced Assembly Costs
A well-designed custom spring can simplify assembly, reduce part count, or integrate multiple functions into a single wireform. This can cut downstream costs and improve manufacturability – advantages that are rarely possible with OTS alternatives.
4. Enhanced Product Reliability
In critical applications – from implantable medical devices or aerospace mechanisms – failure is not an option. Custom spring design allows for tighter tolerances, advanced testing, and process validation, ensuring the component performs as expected under demanding conditions.
5. More Design Freedom
Custom components free you from the constraints of catalog options. Whether you need a spring to fit into a curved cavity, a wireform that acts as both a contact and a mechanical stop, or a compression spring with ultra-low hysteresis, we make it possible.
Custom Small Spring Manufacturing at HyTech:
- Expert Engineering Support – We work directly with your design and R&D teams to prototype and refine springs or wireforms that meet performance and manufacturability goals.
- Micro and Miniature Specialization – Few manufacturers can match our experience in producing reliable parts at extremely small scales, including medical-grade springs and micro wireforms for wearable or implantable devices.
- Advanced CNC and Wireforming Technology – Our equipment includes precision CNC coilers and custom tooling capabilities that ensure repeatability and quality at any volume.
- ISO 13485 & ISO 9001 Certified – Quality is built into every process, with rigorous traceability and documentation to meet regulatory standards in medical, aerospace, and beyond.
The Industry’s Leading Manufacturer of Micro Wire Spring Components
While off-the-shelf springs may be suitable for basic applications, they often fall short in high-performance, miniaturized, or mission-critical products. Custom spring design unlocks better fit, function, reliability, and innovation — ultimately giving your product a competitive edge.
At HyTech Spring & Machine, we don’t just manufacture parts. We provide solutions that are uniquely optimized, engineered, and built around the performance and reliability needed for your end products.
