Although it sounds more like something from a sci-fi movie, miniaturisation is nothing new. From generating feedback in hand-held gaming controllers, precision actuation of aircraft systems or controlling robotic arms performing life-saving surgery, miniaturisation is all around us, carrying mechanical functionality on a very, very small scale. The challenge of miniaturisation is how to transfer control and movement into the smallest of spaces, reducing weight and allowing mechanical engineering to reach into places that no-one has gone before (yes, it does go into space as well!).
TFC is playing its part in this science ‘reality’, by designing Smalley® Wave Springs into ever smaller applications. The beauty of Wave Spring technology is understood and accepted to be a significantly reduced space envelope and less weight compared to a traditional coil spring solution. Apart from the obvious space and weight advantages, the big prize is achieving equivalent spring force in a smaller package.
When faced with the engineering challenge of miniaturisation, key questions often revolve around:
1. How can the already limited installation space be better utilised?
2. How can the overall size of an assembly be further reduced?
Wave Springs from TFC’s Smalley® portfolio frequently prove to be the solution. In the production of medical and dental assemblies, for example, they already proved a success when it comes to achieving spring travel, preload and return forces. The reason: compared to conventional round wire springs, these wave springs (made from flat wire) require up to 50% less axial space and slightly less radial space whilst achieving the required spring characteristics.
In other industries such as gaming, medical, aerospace, automotive, biotech and consumer electronics, this additional fraction of space can enable crucial and potentially competitive optimisations, even under the strict requirements of some incredibly challenging applications. These are just a few sectors where miniaturisation is playing a key role.
Precision engineering of miniature mechatronics is becoming an increasingly prevalent feature in a variety of applications, as electronic control moves into almost every mechanical aspect of modern life.
Only 3.0 mm in Diameter?
That’s right! Using a precision edge coiling process pioneered by Smalley®, Wave Springs can be coiled to just 3mm diameter. This manufacturing technique allows for prototypes and high-volume production to be produced quickly and precisely. Of particular importance for some miniature mechatronic assemblies (Medical, Aerospace, for example) is the ability to mass-produce Wave Springs in special materials, including stainless steel, titanium, and superalloys. TFC’s Smalley® Wave Springs are available from stock in sizes down to 5mm and can be custom designed to 3.0mm diameter.
Many designers focus on Crest-to-Crest® Wave Springs. These springs feature continuous multiple turns and are available in two variants: plain ends or with 360° shim ends. These designs are known to achieve the greatest installation space reductions. Additionally, TFC offers single-turn Wave Springs with gaps or overlapping ends for simple preload devices and Nested Wave Springs with multiple, continuously overlapping turns. The spring rate of such a Nested Wave Spring increases proportionally with the number of turns, allowing for very high preload forces.
We can help with your design
TFC’s Engineering team can work with you to identify the optimal solution and supply prototypes as well as serial production through the same manufacturing process thanks to our exclusive relationship with Smalley® the global leader for this technology. Contact us today to share your design challenge and we’ll spring into action to help you realise your quantum level ambitions!
Follow us on LinkedIn, visit www.tfc.eu.com, email us at enquiries@tfc.eu.com or call us on +44(0)1435866011. Request a sample pack here.
