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Design and Coiling of Music Wire Torsion Spring for the Consumer Electronics Industry

Music Wire Torsion SpringAn electronics customer approached Perfection Spring & Stamping Corp. for a solution to simplify an existing product while increasing its cycle time and lowering the cost of production. The original product, a music wire double extension spring with hook ends, was used in a television application and was not meeting cycle time requirements consistently. After deconstructing the original spring and producing several new prototypes, our engineers at Perfection determined that the best way to serve our client was to redesign the part as a double torsion spring.

As seen in the photo comparison, the simpler design actually yields results beyond the customer's design requirements. In addition to increased performance, the cost savings on the annual 12 million piece production output is substantial. We achieved this success through our Itaya CNC Spring Former, producing the necessary tooling for the former to manufacture the part quickly and efficiently. Working within tolerances of ± .005", the new music wire double torsion spring measures 4" long, with a .75" width and a wire thickness of .090". Our customer could not have been more pleased when our work exceeded expectations and cut costs, a success for both the client and for us.


Music Wire Torsion Spring Specifications

Product Description This Music Wire Torsion Spring was manufactured to replace a double extension spring for increased life cycle time, and is used within a Television application.
Capabilities Applied/Processes Design
  • Redesign Spring for
    • Increase Cycle Time
    • Lower Cost
    • Lower Maturely Usage
    • Less Stress
Spring Coiling
Equipment Used to Manufacture Part Itaya CNC Spring Former -MCS30
Tooling Type
  • CNC Tooling & Cams
  • 6 Stations
Overall Part Dimensions Material Thickness: .090"
Length: 4.0"
Width: .75"
Tightest Tolerances ±.005"
Material Used Music Wire
Material Finish Zinc & Yellow Di-Chromate
Features/Benefits Increased Life Cycle Expectancy
Simplified Design
In Process Testing/Inspection Performed
In-Process Real-time SPC of Critical Dimensions
CMM Measurement
Cycle Testing
Salt Spray Testing
Dimensional Results Reporting
Control Plan
Process Flow Diagram
Failure Mode and Effects Analysis (FMEA)
Gage Repeatability
Reproducibility Variable Data Report
Raw Material Chemical Composition Results
MSDS - Material Safety & Data Report/Substances and Materials
Industry for Use Consumer Electronics
Volume 12,000,000 Pieces
Packaging Bulk Pack Corrugated Packaging
Lead Time Tooling: 2 Weeks
Production Parts: 4 Weeks
Delivery Location Indiana
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Music Wire Torsion Spring

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