Full contact springs are precision-engineered components designed to deliver uniform force distribution across their entire surface, ensuring optimal performance in high-stress environments. At Handa Spring, we combine decades of expertise with cutting-edge technology to manufacture springs that meet the rigorous demands of industries such as automotive, aerospace, medical devices, and renewable energy. This guide dives deeper into the science, applications, and innovations behind our full contact springs, positioning HANDA as your global leader in spring solutions.
2. Advanced Design Principles of Full Contact Springs
2.1 Geometric Optimization
Unlike conventional springs, full contact springs feature a unique helical design that eliminates stress concentration points. Key geometric parameters include:
Pitch-to-Diameter Ratio: Optimized for balanced load capacity and flexibility.
Coil Count: Tailored to application-specific deflection requirements.
End Configurations: Closed-and-ground ends for stability or open ends for dynamic applications.
2.2 Material Science Innovations
Our springs are crafted from advanced alloys to meet diverse operational challenges:
High-Carbon Steel (SAE 1074/1085): Ideal for heavy-duty industrial machinery with tensile strengths up to 2,300 MPa.
Stainless Steel (Grade 316): Corrosion-resistant for marine and chemical processing equipment.
Elgiloy® Alloy: Combines high fatigue resistance with non-magnetic properties for medical imaging devices.
Titanium (Grade 5): Lightweight yet durable for aerospace applications.
Surface Treatments:
Electropolishing: Reduces surface roughness to ≤0.2 µm Ra for low friction.
Dacromet Coating: Provides 1,000+ hours of salt spray resistance.
PTFE Coating: Enhances chemical resistance and reduces wear in high-cycle applications.
3. Technical Specifications and Performance Metrics
3.1 Load-Deflection Characteristics
Our springs undergo rigorous testing to ensure linear load-deflection curves, with tolerances as tight as ±5% of the nominal load.
3.2 Fatigue Life Analysis
Testing Standards: ASTM E606 for strain-controlled fatigue testing.
Results: HANDA springs achieve >1.5 million cycles at 75% of maximum load capacity.
3.3 Environmental Resilience
Temperature Range: -60°C to +300°C (Inconel 718 variant).
Vibration Resistance: Compliant with MIL-STD-810G for military-grade applications.
4. Industry-Specific Applications
4.1 Automotive Innovations
Electric Vehicle (EV) Battery Packs: Our springs provide vibration damping for lithium-ion cells, extending battery life by 20%.
Autonomous Vehicle Sensors: Precision springs ensure consistent contact in LIDAR and radar systems.
4.2 Aerospace Breakthroughs
Landing Gear Systems: Titanium springs reduce weight by 40% compared to steel counterparts.
Satellite Mechanisms: Radiation-resistant alloys ensure reliability in space environments.
4.3 Medical Device Engineering
Surgical Robotics: Biocompatible Elgiloy® springs enable precise force control in minimally invasive tools.
Implantable Devices: MRI-compatible materials prevent interference in pacemakers.
