Leading Supplier of Wire Forms and Springs for the Construction Power Tool Industry

Customer Wire Form Challenge

The wire form appears simple at first glance, but requires many operations to manufacture. One end of the wire is machined to a smaller diameter so that the final diameter after thread rolling is the same as the original wire diameter. The sharp ends are then broken or chamfered. The middle of the wire is swaged to form teeth that can grip into a wooden rafter. There are multiple bends, including an offset bend to both sides of a loop, as well as a bend in the end that butts against the other side. The bending is a complicated operation, but our top-notch CNC wire-bending machinery and engineers can handle it.

Master Spring Solution

In order to compete against this customer’s overseas component suppliers, we removed as much labor from the production process as possible. We automated multiple operations to create a flexible production cell that includes a CNC wire former, a turndown, chamfer, thread and mill machine, a press and a robot. The production cell starts with a coil of wire and ends with a formed belt hook that includes the threads and swaged wings. Three proven, local vendors provide the required special heat treating, electroless nickel plating and nylon patch application to the thread.

Results

With Master Spring’s wire forming knowledge, automated production process and strong customer support, our OEM customer receives better quality wire forms and springs, shorter lead times and competitive pricing. We offer a better value than any overseas supplier.

Customer Torsion Spring Challenge

The customer needed a double torsion spring that not only worked but would stay fastened to the magazine latch-release assembly. The magazine latch release spring’s legs each had one 90-degree bend and butted against each other through the center hole of its plastic-button mating part. One leg of the latch-release spring would occasionally dislodge from the assembly if the other leg end pushed it out. The customer needed a magazine latch-release double torsion spring that stayed in place once installed. They did not want to make a change to the plastic-molded mating part.

Master Spring Solution

Upon seeing how the torsion spring’s leg ends easily moved back and forth out of the hole of the magazine latch-release button, our engineer and skilled machine technician realized the problem. The legs were too far from the button’s center hole. They determined where bends were needed in each leg to bring the torsion spring legs closer to the button’s center hole. Our skilled machine technician quickly programmed the design changes and sent samples to our customer the next day.

Results

This double torsion spring is a great example of Master Spring’s design expertise. By putting extra bends in each leg, we designed and manufactured a double torsion spring that fit closer to the assembly so the magazine latch-release spring would stay secure to the button.