Flat Wire Springs
Special profiles

Flat Wire Springs

Square, flat and profile wire improves load, contact area or energy storage in limited space. Section orientation, corner radius and twist are critical.

Square / flatSpace efficientCustom section
DESIGN WINDOW

Typical capability range

Use these values for early selection. Final dimensions, tolerances and loads are confirmed by engineering review and approved samples.

Wire
Square/flat
Cross-section
Custom
Surface finish
Optional
Typical use
For electrical contacts, precision mechanisms, clamps and high-load assemblies
ENGINEERING OPTIONS

Materials, forms and quality controls

01

Material options

  • High-carbon flat wire: load and energy storage
  • Stainless flat wire: corrosion and cleanliness
  • Copper-alloy strip: conductive contacts and clips
02

Forms and processes

  • Square, rectangular and custom sections
  • Coils, clips, contacts and spring tabs
  • Orientation control and local bends
03

Critical inspection

  • Section width, thickness and corner radius
  • Twist and orientation at critical locations
  • Load, contact face and edge damage
APPLICATION FIT

Typical applications

Square or flat wire springs designed for higher load and contact area in compact spaces

01

Package efficiency

High load or broad contact in compact mechanisms.

02

Electrical contacts

Switch, battery, clamp and conductive assemblies.

03

Energy and clamping

Power springs, clips and precision mechanisms.

DESIGN NOTES

Engineering notes

Rectangular-section orientation strongly changes bending stiffness. Show width and thickness relative to bend plane or spring axis.

Profile materials can carry minimum purchase quantities and longer lead times. Early review prevents an uneconomic sample design.

RFQ CHECKLIST

Include with your RFQ

  1. 01 Section width, thickness, radius and orientation
  2. 02 Material condition and edge quality
  3. 03 Bend radius and twist limit
  4. 04 Travel, load or contact force
  5. 05 Finish, mating face and volume
Request Engineering Review →
FAQ

Common design questions

Can a round-wire design be changed directly to flat wire?

No. Section inertia, stress, springback and material condition differ and require recalculation and sampling.

Why specify corner radius?

It affects stress concentration, fit, contact area and coating coverage and is a functional section parameter.