Common Mistakes to Avoid When Choosing a Compression Spring

When selecting a compression spring for aerospace or electronics applications, every detail matters. A small oversight can result in spring failure, costly delays, or even full system malfunction. At Katy Spring, a custom spring manufacturer based in Texas, we’ve seen how preventable mistakes can impact even the most advanced projects.

Whether you’re an engineer designing high-reliability components or a buyer sourcing precision parts, this guide will help you avoid the most common spring design mistakes and improve your decision-making process.

1. Not Matching the Spring to the Application

A compression spring that performs well in one device may fail in another. One of the biggest mistakes is choosing a spring based on standard sizing instead of actual application needs.

Key issues to watch for:

• Using a generic spring without calculating load or cycle conditions
• Overlooking operating environment (temperature, vibration, corrosion)
• Ignoring motion limits, space constraints, or mounting methods

Tip: Ask yourself:

• Will the spring handle repetitive cycles?
• Does it need to absorb shock or maintain force over time?
• Is it exposed to chemicals or heat?

Matching the spring to the specific system is step one in preventing failure.

2. Overlooking Material Selection

The spring’s material affects its lifespan, fatigue resistance, and corrosion tolerance. In aerospace and electronics, where precision and longevity are critical, using the wrong material can lead to early failure.

Common material mistakes:

• Using music wire in corrosive or high-temperature environments
• Failing to choose non-magnetic alloys in electronic assemblies
• Skipping surface treatments or heat processing for fatigue resistance

Better material choices:

• Aerospace: Inconel, Elgiloy, stainless steel for extreme performance
• Electronics: Beryllium copper or phosphor bronze for conductivity and reliability

As a custom spring manufacturer, Katy Spring can recommend and supply materials that align with both your performance needs and industry standards.

3. Misunderstanding Load and Deflection Specs

Another frequent mistake is misjudging how much force the spring can take or how far it can compress without damage.

Watch out for:

• Exceeding the spring’s solid height, leading to permanent deformation
• Underestimating required spring rate (k) for the desired force
• Forgetting to account for initial tension and pre-load conditions

Smart practice:

• Always calculate the spring’s working range
• Include deflection limits in your design parameters
• Confirm with your spring manufacturer in Texas that tolerances meet your application

4. Ignoring Fatigue and Lifecycle Demands

Spring failure is often caused by fatigue, especially in high-cycle environments like aviation or electronics.

Mistakes that reduce spring life:

• Using springs outside their fatigue-tested range
• Allowing stress levels to exceed safe limits during operation
• Failing to test springs under actual usage conditions

For mission-critical systems, fatigue life should never be an afterthought. Katy Spring provides life cycle testing and engineering support to help you choose springs built for longevity.

5. Settling for Standard Instead of Custom Solutions

While off-the-shelf springs may seem convenient, they rarely offer the ideal fit, especially in tightly controlled aerospace and electronics systems.

Risks of standard springs:

• Poor fit leads to inconsistent performance
• Need for last-minute redesigns
• Compromised safety or functionality

Why custom is better:

• Exact specs for force, space, deflection, and finish
• Faster integration with your design
• Reduced downstream problems

Working with a custom compression spring provider like Katy Spring ensures your design meets both form and function without compromise.

Final Thoughts: Avoid Failure, Choose Precision

Compression springs are small, but the risks of choosing the wrong one are massive, especially in high-performance industries like aerospace and electronics. Avoiding these five mistakes helps you ensure your project runs smoothly and safely.

Need Expert Support? Katy Spring is a trusted spring manufacturer in Texas with decades of experience providing custom compression springs to engineers and buyers in critical industries. Our team helps you avoid costly spring design mistakes with custom solutions, fast lead times, and proven results.

Contact us today to discuss your project and get a quote from a reliable partner in precision spring manufacturing.